Radio frequency identification system for tracking and managing materials in a manufacturing process

ABSTRACT

A process management system uses a radio frequency identification (RFID) detection system in the form of, for example, a phased array antenna based RFID detection system to track and manage material storage and flow in a manufacturing process or plant. The process management system operates in conjunction with the various machines that implement manufacturing stages or steps of the manufacturing process to assure that the correct materials and processing procedures are used at or on the various production machines of the process to produce a particular product as defined by a job number or job order. The process management system is thereby able to increase the efficiencies of the plant and to increase the quality of the plant production by reducing or eliminating waste, manufacturing errors and shipping errors in the production facility.

RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 14/950,192, entitled “A Radio FrequencyIdentification System for Tracking and Managing Materials in aManufacturing Process,” filed Nov. 24, 2015, which is a continuationapplication of U.S. patent application Ser. No. 14/190,453, entitled “ARadio Frequency Identification System for Tracking and ManagingMaterials in a Manufacturing Process,” filed Feb. 26, 2014 and issued asU.S. Pat. No. 9,224,125 on Dec. 29, 2015, which is a continuationapplication of U.S. patent application Ser. No. 13/857,616, entitled “ARadio Frequency Identification System for Tracking and ManagingMaterials in a Manufacturing Process,” filed Apr. 5, 2013 and issued asU.S. Pat. No. 8,690,057 on Apr. 8, 2014, which is a continuationapplication of PCT/US13/29408, entitled “A Radio FrequencyIdentification System for Tracking and Managing Materials in aManufacturing Process,” filed Mar. 6, 2013 which claims the benefitunder 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No.61/607,406, entitled “Automation Project,” filed Mar. 6, 2012 and U.S.Provisional Patent Application Ser. No. 61/708,518, entitled “A RadioFrequency Identification System for Tracking and Managing Material Flowin a Manufacturing Process,” filed Oct. 1, 2012. The present applicationclaims priority from all above-referenced applications and thedisclosures of all above-reference applications are hereby expresslyincorporated by reference herein.

TECHNICAL FIELD

The present disclosure generally relates to using radio frequencyidentification (RFID) technology to advantageously track, manage andcontrol the flow and or positions of material, such as inventory items,within a manufacturing process or an inventory storage facility, to makethe tracking and retrieval of inventory items more automatic andefficient.

BACKGROUND

Many manufacturing processes today are highly automated. However, insome industries, manufacturing processes still require manual operationand/or human intervention. An example industry with manually intensivemanufacturing processes is the corrugated packaging industry, whichtypically produces corrugated boxes, point-of-purchase displays, andother kinds of paper based protective and distribution packaging.

In a typical corrugated plant, the manufacturing process can begenerally divided into four stages. In the first stage, rolls of papermaterial, called rollstock, are received and stored in a rollstockinventory area. In the second stage, the paper rolls are transferred toa wet end area of a corrugator or corrugation machine where the rollsare converted into a continuous corrugated board by gluing multiplelayers of paper together in some manner, such as gluing a layer ofcorrugated paper with one or two layers of smooth paper. At the end ofthe corrugator machine, the corrugated board or paper is cut into sheetswhich are stacked before being placed in a work in process (WIP) area towait for further processing. In the third stage, the stacks ofcorrugated sheets are delivered from the WIP area to a finishing areawhere machines typically called folders and gluers convert the sheetsinto boxes and other packaging or display products through operationssuch as die-cutting, printing, stapling, folding and gluing. During thisstage, the boxes or other packaging and display products may be printedusing, for example, printing plates or may be painted to providegraphics on the products. In the fourth stage, finished goods coming offthe finishing area are banded and are palletized to get these finishedgoods ready for either storage in a warehouse or dispatch and deliveryto customers.

In each stage of the manufacturing process, various manual operationsare typically performed. These manual operations are labor intensive andare generally prone to human errors, thereby creating many problems andinefficiencies in the corrugated plant. Such problems occur in inventorymanagement where each received roll must be manually labeled to beregistered in the rollstock inventory. The location of a roll in therollstock area needs to be recorded so that the whereabouts of the rollcan be tracked. However, if a worker forgets to record the location of aroll or makes an error in the recording of the location of a roll, thenthe roll may become lost in the inventory. Poor inventory management mayalso cause a worker to transfer a wrong roll from the rollstock area tothe wet end area of the corrugator machine. If the error is notrecognized, then the wrong roll will be used in the manufacturingprocess resulting in the production of the wrong type of corrugatedmaterial or paper, increased cost and poor quality. If the error isrecognized, then the worker must go back and spend additional effort tomanually search for the correct roll. Moreover, if the correct rollcannot be found, then the worker may be forced to make a managementdecision by choosing a different roll. As a result, costly unauthorizedupgrades may occur in which a more expensive roll is used to make afinal product than is needed or called for by a particular manufacturingjob.

Moreover, in many cases, it is difficult to track and manage partialrolls, which are rolls that have been used for one or more jobs, butwhich still contain paper material thereon. In particular, operatorstypically know the approximate amount of paper on a particular rollwithin the rollstock area when the roll has never been used or when theroll is first added to the inventory. However, after use, in which someof the paper from a particular roll is removed, the roll is removed fromthe corrugator machine and is returned to inventory. In these cases, itis necessary to record the amount of paper used from the roll during aparticular manufacturing job, which is typically a manual process. Ifthis record keeping is not performed or is performed inaccurately orinconsistently, operators generally do not know how much paper is on aroll or do not trust the records of how much paper is on a roll. Inthese cases, operators typically opt to use a new (previously unusedroll) for a job instead of a partial roll which may or may not havesufficient paper thereon for the job, to assure that the job can becompleted without running out of paper on the roll. This procedure leadsto the existence of many partial rolls in inventory, which take up spaceand increase manufacturing costs of the plant because these rolls neverget used, or are not matched correctly to the size of the job, therebycreating wasted material.

Other problems can be found in process flow management of processeswhere procedures require workers to manually track or label intermediateproducts and finished goods so that the products can be located anddelivered to the next processing stage. For example, intermediateproducts such as stacks of corrugated sheets must be manually labeledwith proper job order numbers in the WIP area to ensure proper deliveryto proper work stations in the finishing area. Likewise, finished goodscoming off the finishing area must be manually labeled with properbanding sequence numbers so that workers can employ proper bandingsequences in the banding machines. However, mislabeling or failure tolabel the intermediate products may cause considerable downtime ordelays in the manufacturing process. Furthermore, errors in manuallabeling, may result in costly consequences if the products go missingor the wrong products get made, for example, by having the wrongintermediate products delivered to the work stations in the finishingarea or by having the intermediate or finished products get banded usingan incorrect banding procedure because a wrong product number or bandingsequence number was used to activate the banding sequence.

Further problems exist in shipping management where the banded finishedgoods must be manually documented in a loading bay so that a driver canfind and ship the correct products to customers. Due to timeconstraints, this type of manual documentation is rarely performed. As aresult, many times, the needed product is not at the correct location sothe driver or loader has to spend a great deal of effort to look for theproduct in the loading bay. Once the driver finds the correct productand finishes loading the truck, the driver must account for anyunder/over amount against a customer shipping order. Errors andomissions in the manual documentation process can lead to a myriad ofshipping-related problems such as loading the wrong products on a truck,recording the wrong products as being shipped, not recording theproducts that are shipped, having under/over shipment of products, etc.These problems affect the overall business by making customers feeldissatisfied and distrustful, as well as increasing costs.

Many corrugated plants have adopted the use of barcode technology toaddress some of the abovementioned problems. A barcode is an opticalmachine-readable representation of data relating to an object that isattached to the barcode. While the use of barcodes offers an improvementin accuracy over manual labeling, manual operations are still neededbecause human operators must place barcode readers in a directline-of-sight to the printed barcode in order to register a read. Thus,many problems still exist in corrugated plants that use barcodes. Forexample, problems exist in inventory management where each received rollis registered in the rollstock inventory by manually or automaticallyplacing and scanning a barcode on the roll, and a barcode on the side,or the ceiling, of an inventory aisle where the roll is placed. However,if workers forget to scan both barcodes when storing a roll, or whenbarcode readers fail, then the roll becomes lost in the inventory. Thus,despite the use of a barcode system, the location of a roll in therollstock still typically needs to be manually recorded. Moreover, if aneeded roll cannot be located in the rollstock, then manual searchingand scanning must be conducted in order to determine the whereabouts ofthe roll. Problems also exist in process flow management procedures thatuse barcodes. In particular, currently, workers must manually scan thebarcode on the products or rolls before moving the rolls or finishedproduct to the next processing or delivery stage where another manualscan takes place to validate the movement. Time constraints and barcodereader failures often compel workers to forgo such scans, which mayresult in costly errors in the manufacturing process. Furthermore, inlocations where outdoor storage is an option, barcode readers often failbecause the readers cannot read in sunlight or bright areas. Whenscanning equipment fails, workers must enter information and datamanually, which prompts the same type of human errors that can occurwith manual labeling. Still other problems exist in shipping managementwhere drivers must perform multiple scans to ensure that the correctproduct is going to the correct vehicle for shipping. However, due totime constraints and other factors, drivers rarely perform all thenecessary scans, which result in the wrong products being shipped andthus leads to dissatisfied customers and waste.

Printed barcodes have other shortcomings as well. A barcode can beeasily damaged (e.g., outdoor storage areas), and if the barcode getsripped, soiled or torn off, there is no way to make a proper scan. Also,reading a barcode may be time-consuming if the barcode is not properlyoriented to the reader. Thus, with a barcode system, a large amount ofmanual data collection activity is still needed, which leaves themanufacturing process manually intensive and dependent on humanintervention.

To provide improvement over barcodes, the use of radio frequencyidentification (RFID) technology has been introduced in some portions ofsome manufacturing plants. A conventional RFID system uses stationary orhand-held RFID readers to identify RFID tags attached to objects. Unlikebarcodes which must be physically located next to and be in close ordirect proximity to the barcode reader in order to read, RFID technologydoes not typically require a tag to be in direct proximity to thereader. However, RFID technology still requires some line-of-sightcommunication between the reader and tag in order to register a read.Also, unlike barcodes, which offer read-only capability, each RFID tagmay be read and write capable, meaning that information can be alteredin the tag. Currently, the use of RFID tags in corrugated plants islimited to inventory management, in which each paper roll, for example,may have an associated RFID tag inserted manually into the core of theroll that allows the roll to be registered in the rollstock inventorywhen the roll passes near a stationary reader. This remote reading ofthe RFID tag eliminates manual operations such as manually labeling orscanning the roll, but manual operations such as removing the core plugto manually insert the RFID tag still remain.

While the problems associated with not registering or improperlyregistering the roll in the inventory may be mitigated with RFID tags,the roll may still become lost in the inventory because the location ofthe roll in the rollstock still needs to be manually recorded. Moreover,misplaced rolls can result in tedious manual searches because stationaryRFID readers cannot be used to locate arbitrarily placed rolls.

More particularly, one of the main problems with the current use of RFIDin corrugated plants is that the stationary RFID readers must be placedat specific spots or locations within the plant and thus only providenodal reading of tags. For example, RFID readers are typically placed atdoorways to define a portal or are placed at or near a manufacturingarea to define a read node. The tagged product can only be read at thesenodes within the plant, which leads to a lot of problems. If a taggedproduct is picked up from one manufacturing area and is transferred to asecond manufacturing area without going through a read node, then thelocation of the tagged product is still lost or not accurately tracked.Moreover even when a transfer is completed properly, the transfer is notrecognized until the tagged product reaches the RFID reader defining theportal or read node near the second manufacturing area. Moreover, theproduct is only known to be at or near the read node. As a result,movement of a tagged product within a plant is tracked inconsistentlyand very inaccurately using typical RFID technology. Stationary readersalso have a problem in that the signals sent out by the readers tend to“reflect” off objects such as forklift or other objects, and createspurious reads.

Because RFID technology, as currently used in corrugated plants,requires the use of a number of fixed or stationary RFID readers thatcan only detect the passage of a tag past a particular point, plantshave used hand-held RFID readers to assist in tracking the whereaboutsof products or raw materials, such as rollstock. However, the use ofhandheld readers still requires human operators to carry the readers toa point where tagged objects are located in order to read the tags onthe products, in which case the amount of manual operations is similarto that of the barcode system.

Some efforts have been made in the pulp and paper industry to resolvethe problem of tracking the location of rolls of material in inventorywithout the use of handheld readers. As disclosed in U.S. Pub. No.2004/0102870, an RFID reader is placed on a forklift which moves thereader around a warehouse to assist in locating particular tagged rollsof paper. However, this approach only works when the forklift is inclose proximity to the rolls to which the tags are attached and so theforklift driver still has to know the approximate location of the rollin the warehouse to begin a search for a particular roll. Moreover, thetags are directional and the RFID reader requires some line-of-sight tothe tags. Thus, if a tag is on one side of the roll and the forklift ison the other side, then the tag cannot be read by the reader.

Moreover, aside from inventory management, RFID usage has not beenincorporated into other processing functions such as process flowmanagement or shipping management, in corrugated plants. Some effortshave been made in to use RFID to manage flow through a process, butthese efforts are for throughput management only and do not increaseproduct quality or manufacturing efficiencies within a plant. Forexample, U.S. Pat. No. 7,970,484 discloses a method that uses RFID tagson boxes containing products flowing through a manufacturing line togenerate stop and go signals to control the throughput of the productionprocess. However, the method only functions to control the throughput ofthe process, and does not actually control the flow of the processmaterials, for example, by determining what materials are needed at whatlocations in the process or where materials should be sent in order toassure that the proper or desired final product is being made.

SUMMARY

A manufacturing process and inventory management or tracking system usesa radio frequency identification (RFID) detection system which may be,for example, a phased array antenna based RFID detection system, totrack and manage material storage and flow of material in amanufacturing process or plant. The management or tracking systemoperates to track and to provide the location of various inventorywithin an inventory region of the plant and may operate in conjunctionwith the various machines that implement manufacturing stages or stepsof the manufacturing process to assure that the correct materials (e.g.,inventory, machine parts, etc.) and processing procedures are used at oron the various production machines of the process to produce aparticular product as defined by a job number or job order. The processmanagement system is thereby able to increase the efficiencies of theplant and to increase the quality of the plant production by reducing oreliminating waste, manufacturing errors and shipping errors in theproduction facility.

Generally speaking, the management system employs a detection andtracking system that uses RFID tags attached to various differentmaterials in the plant, such as raw materials, intermediate products orfinished goods, to detect and track the location of these materials atany time and or at any location in the plant including in an inventoryregion of the plant (including a spare parts inventory) and amanufacturing region of the plant. In one case, the RFID detection andtracking system uses phased array antennas disposed within the plant toscan one or more areas in the plant periodically, so as to detect thelocation or position of all of the RFID tags in that area in a threedimensional (3D) view. In another case, the RFID detection and trackingsystem may use multiple spaced apart antennas to scan a region using atriangulation technique to detect the location of RFID tags within theregion. The process management system may use the current location ofthe RFID tags to determine where the materials needed for a productionrun are located in the plant by associating the RFID tags on variousplant materials with job numbers defining products to be produced. Thejob numbers may also be associated with or define manufacturing stepsthat need to be taken in the plant to produce the product associatedwith the job number. The process management system may then implement ormanage a particular production run used for a job number by tracking theRFID tags for the various materials to be used in the production run forthe job number during the production run to assure that the correctmaterials are used in the production run and to assure that the correctprocessing steps or procedures are used at each of the various stages ofthe production run. If desired, the process management system mayinterface with one or more controllers within the plant or themanufacturing process to prevent or halt operation of the productionmachines unless the correct materials are at the correct inputs of theproduction machines. Alternatively or additionally, the processmanagement system may assure that the correct production programming orprocedures are used at each stage of the production run by, for example,loading the correct production programming into the machines based onthe RFID tags associated with the product or material being provided tothe machine. As part of this process, RFID tags may be applied tointermediate products created during the manufacturing run to enable theprocess management system to track these intermediate products, so as toassure that the correct intermediate products are provided to thecorrect processing machines at the correct time when implementing amulti-stage production run for a job number. Still further, in somescenarios, records stored for RFID tags identifying a certain type ofintermediate product may be changed or altered to reflect changes in theintermediate product as the product being created flows through theproduction facility from one stage or step of manufacturing to anotherstage or step of manufacturing. In this manner, the process managementsystem may assure that the production run for a particular job uses thecorrect raw materials and that the production equipment is configured orset up to implement the correct manufacturing and packaging steps for ajob number which, in turn, helps to assure that the correct product ismade for a job number.

Still further, the management system may use the RFID tracking system toperform inventory management and control as well as to perform shippingmanagement and control. In particular, the process management system maydetect, track or scan all of the inventory in an inventory area todetermine what inventory is present (based on the RFID tags detectedduring the scan), and provide a 3D view of the location of each piece ofinventory. This feature enables the process management system to directplant personnel to the correct location in the inventory area to get orobtain the correct materials to be used in a production run. Stillfurther, the process management system may update records associatedwith RFID tags of material, such as rolls of paper, to indicate or trackthe amount of material left on the roll, for example, or other changesin the material. In a similar manner, the process management system mayuse the RFID tracking system to detect and track finished goods in aloading bay and may use this information to assure that the correctfinished goods are loaded onto the correct truck for shipping to acustomer. This feature reduces shipping errors and can further be usedto automatically create bills of landing defining exactly what finishedgoods are being shipped to the customer.

In one embodiment, an inventory tracking system for use in trackingplacement of physical items within an inventory tracking region of, forexample, a manufacturing plant, includes a radio frequency tag detectionsystem that includes a plurality of radio frequency antennas disposed ina spaced apart manner within the inventory tracking region and adetection controller coupled to the plurality of radio frequencyantennas that controls the operation of each of the radio frequencyantennas to scan a portion of the inventory tracking region and todetect each of a number of radio frequency tags disposed in theinventory tracking region. Here, the detection controller generatesindications of the detected radio frequency tags and the physicallocations of the detected radio frequency tags within the inventorytracking region. Moreover, the inventory tracking system includes atracking system coupled to the radio frequency tag detection system toreceive the indications of the detected radio frequency tags and thedetected physical locations for the detected radio frequency tags withinthe inventory tracking region. The tracking system includes a memory forstoring inventory item information for each of a plurality of inventoryitems, the inventory item information for each of the plurality ofinventory items including an inventory item radio frequency tagidentifier, inventory item identification information defining theidentity of the inventory item, and an indication of the currentphysical location of the inventory item within the inventory trackingregion. The inventory tracking system also includes an access systemthat accesses the memory and provides at least a subset of the inventoryitem information for one or more of the inventory items to a user fordetermining the current physical location of the one or more of theinventory items within the inventory tracking region. The trackingsystem updates the indication of the current physical location of atleast one particular inventory item within the inventory tracking regionas stored in the memory for the at least one particular inventory itembased on the indication of the physical location of the detected radiofrequency tag for the at least one particular inventory item as producedby the detection controller.

If desired, the subset of inventory item information may include anindication of the current physical location of the one or more of theinventory items within the inventory tracking region and/or may includethe inventory item identification information for the one or more of theinventory items. The tracking system may store, for each of theplurality of inventory items, inventory item identification informationincluding two or more defining characteristics of the inventory item andthe inventory item identification information for at least one of theinventory items may include a type of material associated with theinventory item, a source of the inventory item, or an amount of materialassociated with the inventory item.

If desired, the access system may include a user display system thatgraphically displays the current physical location of the one or more ofthe inventory items based on the indication of the current physicallocation of the one or more of inventory items and the user displaysystem may display the current physical location of the one or more ofthe inventory items in a graphical manner juxtaposed with or on anindication of at least a portion of the inventory region. The userdisplay system may display the current physical location of one of theinventory items by displaying an indication of a geographical coordinateat which the one of the inventory items is located, or an indication ofa two dimensional geographical location of the inventory item within theinventory tracking region. Also, the user display system may graphicallydisplay the current physical location of inventory items by displayingan indication of a three dimensional geographical location of one ormore of the items within the inventory tracking region.

Still further, the access system may includes an auditory system thatgenerates auditory signals based on the current physical location of oneor more of the inventory items, may include a visual system thatgenerates lighted signals based on the current physical location of oneor more of the inventory items, and/or may include a tactile system thatgenerates tactile (e.g., vibration) signals based on the currentphysical location of one or more of the inventory items.

The detection controller may include a beam-steering control system,such as an electronic beam steering or a mechanical beam steeringcontrol system that controls the operation of each of the radiofrequency antennas using a beam to scan a portion of the inventorytracking region to detect each of a number of radio frequency tagsdisposed in the scanned portion of the inventory tracking region.

The inventory tracking system may further include an inventory controlsystem that receives the current physical location of at least one ofthe inventory items from the access system and determines if the one ofthe plurality of inventory items is in a desired location. Here, theinventory control system may compare the current physical location ofthe at least one of the inventory items to a desired location of the atleast one of the inventory items as defined by a job identifier or a jobnumber associated with a, for example, manufacturing job that uses theat least one of the inventory items. The inventory control system mayproduce a warning or alert signal when the location of the at least oneof the inventory items associated with the job identifier is not at thedesired location for the inventory item for the job defined by the jobidentifier when running the job. In some situations, the desiredlocation may be associated with a location of one of the inventory itemswithin a manufacturing process during execution of the manufacturingprocess during the job. The inventory control system may further detectmovement of the at least one of the inventory items based on the jobidentifier and may compare the movement of the inventory item with adesired movement of the inventory item as specified by the jobidentifier. If desired, the inventory control system may enable aportion of a manufacturing process to occur based on the detectedcurrent physical location of the at least one of the inventory items.

In another embodiment, a method of tracking inventory within aninventory region includes periodically scanning the inventory regionwith one or more radio frequency antennas to detect one or more radiofrequency tags in the inventory region, each of the radio frequency tagsbeing associated with an inventory item (or in some cases an employeehandling the inventory item), and determining a location for each of theone or more detected radio frequency tags within the inventory regionbased on the detection of the one or more radio frequency tags within ascan, wherein the location for each of the one or more detected radiofrequency tags is resolved to a region less than the coverage area ofthe steerable antennas. The tracking method also includes storing, in acomputer readable memory, for each of the detected radio frequency tags,inventory item information, wherein the inventory item information for aradio frequency tag includes an inventory item radio frequency tagidentifier, inventory item identification information defining theidentity of the inventory item, and current physical locationinformation for the inventory item. The tracking method updates thecurrent physical location information of at least one inventory itemwithin the inventory tracking region as stored in the computer readablememory based on the determined location of the detected radio frequencytag for the at least one inventory item as determined during one or morescans. Moreover, the tracking method includes accessing the storedinventory item information to determine the physical location of the oneor more of the set of inventory items within the inventory region.

The tracking method may further include storing, as part of theinventory item identification information, two or more characteristicsof the inventory item, such as an amount of material associated with theinventory item and a type of material or inventory item. The trackingmethod may also include displaying the physical location of the one ormore of the inventory items within the inventory region on a displaydevice such as by graphically displaying an indication of the currentphysical location of one or more of the inventory items on a userdisplay device juxtaposed with or on an indication of at least a portionof the inventory region or by displaying the physical location of theone or more of the inventory items by displaying at least a portion ofthe inventory item identification information along with an indicationof the current physical location of one or more of the inventory itemson a user display device.

The tracking method may further include generating an auditory signalbased on the current physical location of one or more of the inventoryitems, generating a visual alarm signal based on current physicallocation of one or more of the inventory items, and/or generating othertypes of user interface signals. The tracking method may includeperiodically scanning the inventory region with one or more steerableradio frequency antennas by periodically scanning the inventory regionusing a beam steering scanning technique for each of the one or moresteerable radio frequency antennas.

The tracking method may further include using the physical location ofone of the inventory items as stored in the memory to determine if theone of the inventory items is in a desired location as defined by a jobidentifier, and may include producing a warning signal when the currentphysical location of the one of the inventory items associated with thejob identifier is not at the desired location for the inventory item forthe job identifier. The tracking method may include using the physicallocation of one of the inventory items as stored in the memory to detectmovement of the one of the inventory items within the inventory regionand determining if the detected movement of the one of the inventoryitems is a desired movement based on a job identifier. The trackingmethod may also include enabling or disabling the operation of a portionof a manufacturing process based on the physical location of one of theinventory items.

In another embodiment, a method of tracking inventory within aninventory region includes periodically scanning the inventory regionwith one or more radio frequency antennas to detect each of a pluralityof radio frequency tags in the inventory region, each of the radiofrequency tags being associated with a different inventory item, anddetermining a location for each of the one or more detected radiofrequency tags within the inventory region based on the detection of theone or more radio frequency tags within a scan. The region may bescanned with the radio frequency antennas using a steerable antenna,such as an electronically steerable antenna, or may be scanned withmultiple antennas using a triangulation technique, for example. Here,the location for each of the one or more detected radio frequency tagsis resolved to a region less than the coverage area of the antennas. Thetracking method also includes storing inventory item information in acomputer readable memory for each the different inventory items, theinventory item information for a particular inventory item including aradio frequency tag identifier, inventory item identificationinformation defining the identity of the inventory item, and currentphysical location information for the inventory item, and updating thecurrent physical location information of each of the inventory itemswithin the inventory tracking region as stored in the computer readablememory based on the determined location of the detected radio frequencytag for the inventory items as determined during one or more scans. Thetracking method also includes enabling access to the stored inventoryitem information for each of the inventory items to determine thephysical location of the inventory items within the inventory region.The tracking method may include displaying the physical location of amultiplicity of the inventory items within the inventory region on adisplay device by graphically displaying an indication of the currentphysical location of the multiplicity of inventory items on a userdisplay device juxtaposed on an indication of at least a portion of theinventory region and/or by displaying at least a portion of theinventory item identification information for one of the multiplicity ofinventory items along with the indication of the current physicallocation of the one of the multiplicity of inventory items on a userdisplay device.

In still another embodiment, a method of controlling a manufacturingprocess includes storing manufacturing item information in a computerreadable memory for each of a set of manufacturing items, themanufacturing item information for a particular manufacturing itemincluding a radio frequency tag identifier and manufacturing itemidentification information defining the identity of the manufacturingitem and storing manufacturing process information definingmanufacturing information associated with a manufacturing job. Themanufacturing control method also includes scanning a manufacturingregion in which a manufacturing process occurs with one or more radiofrequency antennas to detect one or more radio frequency tags in themanufacturing region, each of the radio frequency tags being associatedwith a different manufacturing item, and determining if one of themanufacturing items is at a location in the manufacturing process calledfor by the manufacturing process information for the manufacturing jobbased on the identity of the radio frequency tags detected during thescan of the manufacturing process. The manufacturing control method alsoaffects the operation of the manufacturing process if one of themanufacturing items is not at a location in the manufacturing processcalled for by the manufacturing process information for themanufacturing job when the manufacturing process is to be run for themanufacturing job.

The manufacturing control method may affect the operation of themanufacturing process by disabling the operation of the manufacturingprocess when the one of the manufacturing items is not at a location inthe manufacturing process called for by the manufacturing processinformation for the manufacturing job and may disable the operation ofthe manufacturing process by sending an interrupt signal to a controllerthat controls the operation of equipment within the manufacturingprocess to prevent the controller from implementing the operation ofequipment within the manufacturing process. Disabling the operation ofthe manufacturing process may also or instead include sending an enablesignal to a controller that controls the operation of equipment withinthe manufacturing process to enable the controller to implement theoperation of equipment within the manufacturing process only when theone of the manufacturing items is at a location in the manufacturingprocess called for by the manufacturing process information for themanufacturing job. Affecting the operation of the manufacturing processmay in addition or instead include notifying a user if one of themanufacturing items is not at a location in the manufacturing processcalled for by the manufacturing process information for themanufacturing job when the manufacturing process is to be run for themanufacturing job. Notifying a user may include initiating a visualwarning on a user display device associated with monitoring or controlof the manufacturing process, may include providing an audible signal toa user or may include providing a tactile signal to the user.

The manufacturing control method may scan the manufacturing region inwhich a manufacturing process occurs with one or more radio frequencyantennas using one or more for example, steerable, such aselectronically steerable, radio frequency antennas to scan themanufacturing region or may scan the manufacturing region with multipleantennas using a triangulation technique, and may store the detectedphysical location information of each of the manufacturing items withinthe computer readable memory based the location of the detected radiofrequency tag for the manufacturing items as determined during one ormore scans. The manufacturing items may be inventory items of rawmaterial used in the manufacturing process such as paper rolls, glues,or inks used in a packaging manufacturing process and/or may becomponents of a manufacturing machine, such as a dye, a press, or amachine tool. Scanning the manufacturing region in which a manufacturingprocess occurs with one or more radio frequency antennas may includeresolving the location for each of the one or more detected radiofrequency tags to a region (e.g., area or volume) that is less than thecoverage area of each of the one or more radio frequency antennas, suchas to a region or location equal to or less than one square or cubicmeter, one square or cubic foot, one square or cubic inch, as examples.

The manufacturing control method may further include applying a radiofrequency tag to one or more intermediate manufacturing items createdduring a first portion of the manufacturing process (or alternativelycreated by an outside source but to be used in the manufacturingprocess), and the process of scanning the manufacturing region in whicha manufacturing process occurs with one or more radio frequency antennasto detect one or more radio frequency tags in the manufacturing regionmay include scanning a manufacturing region associated with a secondportion of the manufacturing process to detect the radio frequency tagon the one or more intermediate manufacturing process items. Here,determining if one of the manufacturing items is at a location in themanufacturing process called for by the manufacturing processinformation for the manufacturing job may include determining if the oneor more intermediate manufacturing items are in a location called for bya job identifier associated with operation of the second portion of themanufacturing process.

In yet another embodiment, a manufacturing process tracking system forassisting in the operation of a manufacturing process that usesmanufacturing equipment to produce a product, includes a radio frequencytag detection system including one or more radio frequency antennasdisposed within a manufacturing region in which the manufacturingequipment is located and a detection controller coupled to the one ormore radio frequency antennas that controls the operation of the radiofrequency antennas to electronically scan a portion of the manufacturingregion and to detect each of a number of radio frequency tags disposedin the manufacturing region, wherein the detection controller generatesindications of the detected radio frequency tags and the physicallocations of the detected radio frequency tags within the manufacturingregion. The manufacturing process tracking system also includes a radiofrequency tag tracking system coupled to the radio frequency tagdetection system to receive the indications of the detected radiofrequency tags and the detected physical locations for the detectedradio frequency tags within the manufacturing region, the radiofrequency tag tracking system including a tracking memory for storingthe detected physical location for each of the detected radio frequencytags as detected by the radio frequency tag detection system. Likewise,the manufacturing process tracking system includes a manufacturingtracking controller coupled to the radio frequency tag tracking systemthat includes a manufacturing item memory storing manufacturing iteminformation for each of a plurality of manufacturing items, themanufacturing item information for each of the plurality ofmanufacturing items including a manufacturing item radio frequency tagidentifier and manufacturing item identification information definingthe identity of the manufacturing item and a manufacturing processmemory storing manufacturing process information for a manufacturingjob, the manufacturing process information defining manufacturing itemsto be used in or on the manufacturing equipment of the manufacturingprocess when implementing the manufacturing job. The manufacturingprocess tracking system also includes a manufacturing system processorthat determines, based on the manufacturing process information and themanufacturing item information, if a manufacturing item to be used in amanufacturing job is currently located in a location within themanufacturing region called for by the manufacturing job and to producea signal indicative of the determination, the signal adapted to affectthe operation of the manufacturing job on the manufacturing equipment.

The manufacturing process tracking system may operate with manufacturingitems to be used in a manufacturing job that are removable pieces ofequipment used on the manufacturing equipment when implementing themanufacturing job, such as a dye, a press, or a machine tool. Themanufacturing items may also or instead be raw materials or intermediatematerials used in the manufacturing job to produce the product.

The manufacturing system processor may use the signal indicative of thedetermination to produce a control signal that controls themanufacturing equipment to implement the manufacturing job. For example,the control signal may enable the manufacturing equipment to operate.Additionally or instead, the manufacturing process tracking systemprocessor may send operational information to the manufacturingequipment to operate in a particular manner for the manufacturing job.The manufacturing processor may send an error signal, such as an audio,visual or tactile signal, to a user indicating the existence of anincorrect manufacturing item in the manufacturing region for themanufacturing job or a missing manufacturing item in the manufacturingregion for the manufacturing job. The manufacturing processor may sendthe signal to a user interface to indicate whether a manufacturing itemin the manufacturing region is the correct manufacturing item for themanufacturing job, or may produce an audio indication indicating whethera manufacturing item in the manufacturing region is the correctmanufacturing item for the manufacturing job.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating an example inventory and processmanagement system that uses RFID technology to track inputs and outputsto manage or control the process flow in a manufacturing process.

FIG. 2 is a diagram illustrating a manufacturing process used in acorrugated packaging plant in which the inventory and process managementsystem illustrated in FIG. 1 can be used.

FIG. 3 is a diagram illustrating placement of RFID tags on variousobjects used in the corrugated packaging plant shown in FIG. 2.

FIG. 4 is a diagram illustrating the use and development of RFID tagsand their associated data structures in a manufacturing process of thecorrugated packaging plant illustrated in FIG. 2.

FIG. 5 is a diagram representing an example application that tracks RFIDtagged inputs and outputs to manage inventory in the corrugatedpackaging plant shown in FIG. 2.

FIG. 6 is a diagram representing an example application that tracks RFIDtagged inputs and outputs to manage the process flow in a manufacturingprocess of the corrugated packaging plant shown in FIG. 2.

FIG. 7 is a flow chart of an example method that may be implemented bythe process management system of FIG. 1 to track RFID tagged inputs andoutputs to manage or control a manufacturing process.

DETAILED DESCRIPTION

An inventory and process management or tracking system uses RFIDtechnology to track and control the flow of inputs and outputs in amanufacturing process by using a single or a network of steerableantennas, such as beam steerable phased array antennas or other beamsteerable antennas, to provide real-time, three dimensional locationdetection and tracking of RFID tagged materials and goods being used inan inventory or in a manufacturing process. The system uses the detectedlocation and movement of the RFID tagged materials and goods to performvarious steps in managing the flow or use of materials within a processto increase the productivity of the process including inventorymanagement, to increase the production accuracy or quality of productionof the process and to minimize labor costs and other costs associatedwith manual operational errors within the plant or process.

More particularly, the process management system performs inventorymanagement by documenting, tracking and recording the location ofreceived raw materials in an inventory area or region of a plant usingthe 3D RFID detection and tracking system. The system updates theinventory by tracking the movement of the raw materials from place toplace within the inventory area or region to other areas or regions ofthe plant where the raw materials are converted into intermediateproducts and/or finished goods. The system also directs process orproduction activities by first determining the required inputs (e.g.,the raw materials), the required process activities (e.g., the processsteps), and the generated outputs (e.g., the finished goods) in eachstage of a manufacturing process. The system then regulates or managesthe overall process or production flow by tracking and directing themovement of material inputs to and material outputs from eachmanufacturing stage using RFID tags, thereby improving efficiency,reducing downtime and cutting overall costs in the plant. Still further,the system manages the delivery, loading and shipping of finished goodsby tracking the movement of finished goods within a loading bay of theplant to assure that the correct goods (for a particular job order orjob number) are placed onto the correct truck for shipping or deliveryto the customer. The system may also assure that the right number ofgoods are loaded, and may automatically generate, for example inreal-time, a bill of landing including the exact goods loaded onto thetruck. Moreover, if desired, the system may assure that finished goodsare loaded onto a truck in the proper order to assure that unloading thetruck is easier or more efficient when, for example, the truck must makemultiple deliveries to different locations.

FIG. 1 illustrates an example inventory and process management ortracking system 10 including a command system 12 connected to an RFIDdetection and tracking system that includes a network of antenna systems14 (which may be for example, one or more electronically steerablephased array antenna systems each having multiple antenna elements 24)connected to a processor (not shown) that directs or operates theantennas or elements 24 in a manner described in more detail herein andperforms RFID detection and tracking. While the antenna systems 14 mayuse an electronically steerable beam for RFID detection and tracking,other forms of antenna systems including directional antenna systems,for example, mechanically steerable beam antennas such as rotatable ormovable parabolic antennas, Yagi antennas, log periodic antennas, cornerantennas, etc. may be implemented to perform RFID detection andtracking. The command system 12 is also connected to one or more processor manufacturing controllers 16, each controlling process activities inone of a set of manufacturing stages 18 a to 18 d associated with amanufacturing process 19. The manufacturing process 19 may, in thisexample, include an inventory stage 20 and a shipping stage 21, whichare not controlled by the process or manufacturing controllers 16. Withreference to FIG. 1, the manufacturing process 19 includes fourmanufacturing stages or regions, but generally speaking, themanufacturing process 19 could include any other number of manufacturingstages or regions. During operation, material inputs and materialoutputs at each stage or region of the manufacturing process 19 aretagged with RFID tags 22 for identification and tracking. The antennasystems 14, which may be, by way of example, any of the phased arraysystems sold by RF Controls LLC and/or disclosed in U.S. Pub. No.2010/0207738 (the entire disclosure of which is hereby expresslyincorporated by reference herein), are used to detect and track thelocation and movement of the RFID tagged material inputs and materialoutputs and use this tracking information to manage the manufacturingprocess 19 using, for example, the controllers 16. Although FIG. 1illustrates the phased array antenna systems 14 as having three antennaelements 24, the phased array antenna systems 14 in general may includeany number of antenna elements disposed in a one-dimensional pattern(e.g., a line), a two dimension pattern (e.g., a grid) or even a threedimensional pattern.

Generally speaking, the command system 12 includes a processor 25 forimplementing functions, routines and instructions stored in a memory 26,a user interface 29 for accepting user inputs, one or more databases 28for storing data, and a control module 27 for interfacing with theprocess controllers 16 via, for example, an Ethernet connection or anyother desired wired or wireless communication network 30. The processmanagement system 10 of FIG. 1 also includes an RFID module 31 which maybe a detection controller that is part of the RFID tracking system forinterfacing with and potentially controlling the antenna systems 14 via,for example, an Ethernet connection or other type of communicationnetwork 32. Still further, the command system 12 includes acommunication module 33 for communicating with workers and otheroperators. The communication module 33 transmits data to and receivesinformation from various information user terminals or other interfacessuch as a computer station 34, a personal data assistant (PDA) 36, or aheadset 38 via a communication antenna 40 or other visual or audio oreven tactile interfaces. The terminals or interfaces also may be, forexample, a set of lights that change color, may be a tactile devicethat, for example, vibrates in one or more known or predeterminedmanners, may be an audio system that provide an audio signal in the formof a speech signal for example, etc., to indicate the existence ofproper or improper materials at a particular location for a particularmanufacturing or inventory job. However, the communication module 33 maycommunicate with any other type of user interface using any known wiredor wireless communication technologies. Moreover, if desired, the RFIDmodule 31 may be implemented as software run in a processor in the formof edgeware, to preprocess the data received from the antenna systems 14and/or to control the antenna systems 14.

Generally, the RFID module 31 may be an RFID detection controller 31that operates to control or energize the antennas 24 to emit RFIDdetection signals which are received and reflected (in known manners) byRFID tags within the inventory and manufacturing regions 18, 20 and 22.The detection controller 31 receives the signals reflected or emitted bythe RFID tags and collected by the antennas 24 and processes thesesignals to determine the identity of and the precise location of theRFID tags that reflect or emit radiation in response to the detectionsignals emitted by the antennas 24. The detection controller 31 maycontrol each of the antennas 24 of antenna systems 14 to periodicallyscan a location or region covered by the antenna 24 to thereby scan anarea or region for RFID tags within the coverage area or region of theantenna 24.

Generally, the detection controller 31 may periodically scan each areaor region using a phased array antenna system 14 to form a beam and mayeven steer that beam across the region or multiple different regionsusing known phased array beam steering techniques. The detectioncontroller 31 may, alternatively or in conjunction, use a triangulationtechnique based on the RFID signals received at multiple spaced apartantenna elements 24 (either within the same antenna system 14 ordifferent antenna systems 14) to scan an area or region to determine thelocation or position of each RFID tag within the coverage area of theantennas 14. As these detection techniques are well known, the specificsof these techniques will not be described in detail herein. Thedetection controller 31 generally operates using these or otherdetection techniques to resolve the location for each of the one or moredetected radio frequency tags to a sub-region (e.g., area or volume)within the coverage area or location that is less than the entirecoverage area of the radio frequency antenna 24 or 14, such as to aregion or location equal to or less than one square or cubic meter, onesquare or cubic foot, one square or cubic inch, as examples. Here, eachantenna may periodically scan or cover a region that is 5 feet, 10 feet,20 feet, 30 feet, in radius, for example.

The RFID detection controller 31 (which may be a centralized controlleras illustrated in FIG. 1 or which may have a separate controller elementassociated with each antenna 24 or antenna system 14) may cause theantennas 24 or the antenna systems 14 to scan a two dimension area (suchas an area on the floor of the plant) or a three dimensional volume,such as a volume of space around or adjacent to the antennas 24 toresolve locations of RFID tags within two-dimensional areas or regionsor to within three dimensional areas or regions. The antennas 24 orantenna systems 14 may be beam steerable antennas and thus emit adetection signal (radiation) in a directional beam, wherein the beam isperiodically swept through the coverage region (area or volume) of theantenna 24. RFID tags, when swept over by the high strength portion ofthe beam, will reflect or emit an RFID tag signal which is then capturedor detected by an antenna 24 or an antenna system 14 (typically theantenna or system emitting the beam impinging on the RFID tag). Thelocation and direction of the beam and the amount of time, for example,that it takes for the RFID tag to respond may be used to detect the twodimensional or the three dimensional location of the RFID tag using thedetection techniques described above.

However, the antennas 24 or antenna systems 14 may be fixed pattern orfixed beam antennas and thus emit a detection signal (radiation) in aconstant direction or pattern that generally remains the same. In thiscase, multiple spaced apart antennas cover the same region or coveragearea or volume. RFID tags, when exposed to the radiation from theseantennas, will reflect or emit an RFID tag signal which is then capturedor detected by each of the spaced apart antennas 24 or antenna systems14. The detection controller 31 may then use a triangulation techniqueto determine the position of each RFID tag based on signals from two orthree spaced apart antennas 24 or 14. This technique is also referred toherein as a scanning technique. Thus, the description provided herein ofusing one or more antennas to scan an area or region of a plant or otherbuilding or location includes using beam steered antennas to performscans (e.g., by operating an electronic beam steerable antenna or amechanically steerable antenna to sweep over a region), and includesusing triangulation techniques based on signals from multiple differentfixed or non-steerable antennas, or some combination of both. Of course,other methods of scanning a region to detect RFID tags could be used aswell or instead. In any case, the antennas 24 or the antenna systems 14(also referred to as antennas) may be fixed antennas, may beelectronically controllable and steerable phased array antennas, may bemechanically steerable antennas, etc.

In a general sense, the RFID detection controller 31 may use the antennasystem 14 or other antennas 24 to detect and track the location andmovement of the RFID tagged inputs and outputs within inventory(including indoor and outdoor storage areas) and within the plant tohandle or perform inventory management in the inventory stage 20, tocontrol or manage process flows in the manufacturing stages 18 a to 18d, and to manage shipping in the shipping stage 21, all in a manner thatincreases the efficiency of the plant, assures or increases productquality and helps to assure correct material flows within the plant.Beginning in the inventory stage 20, received inputs such as rawmaterials like paper rolls are tagged with the RFID tags 22 (e.g.,mechanically applying the tags) and are stored in an inventory. Thestorage location of the RFID tagged raw material is recorded and trackedby the command system 12 (and in particular by a tracking controllerexecuted in, for example the processor 25) so that the raw materials canbe located in the inventory at any time without the need of a handheldRFID receiver or of a movable receiver on a forklift, for example. Inaddition, external vendors may tag the raw materials with the RFID tags22 to further enhance the process by eliminating manual tagging at theplant.

Moreover, when a job order or production run is started, the commandsystem 12 determines which raw materials to use, and notifies theworkers of the location of the raw materials in the inventory viainformation terminals (e.g., the computer station 34, the PDA 36 or theheadset 38) based on the RFID tag of these materials so that the correctraw materials can be picked up for the job order. In one case, theamount of raw materials (e.g., the amount of paper of a roll) that canbe used for the job order and the amount of raw materials remaining oneach such roll are calculated or are tracked by the command system 12 inorder to keep the inventory stock up to date. Further, in the subsequentmanufacturing stages 18 a to 18 d, required material inputs andgenerated material outputs are tagged with the RFID tags 22 foridentification and tracking by the command system 12. The command system12 determines the required inputs and the required process activities toexecute the job order at each manufacturing stage, and tracks themovement of the tagged material inputs to ensure that the correctmaterial inputs are received at the correct manufacturing stage at thecorrect time (i.e., for the particular job order being run). If thewrong material inputs are received at a particular manufacturing step orprocess by mistake, as detected by the RFID tracking system, then thecommand system 12 may notify a user in some manner and/or may suspendthe process activities in the manufacturing stage until the correctmaterial inputs are in place. The command system 12 may notify a user ofthe problem via, for example, one of the user interface devices 34, 36,38 or via lights, alarms etc. disposed at appropriate places in theplant. In this case, the RFID module 31 (also called a detectioncontroller) and the antennas systems 14 and 24 make up a detectionsystem, while the processor 25 may run a tracking controller usingand/or including the memory 26, and the database 28 which may, in turn,store inventory and manufacturing item information as discussed below aswell as process manufacturing jobs and recipes or manufacturinginformation defining materials and/or equipment to use in one or moremanufacturing jobs.

When the correct material inputs are received or are present at an inputto a manufacturing step or process, the command system 12 may direct orenable the process controllers 16 to execute typical or standard processcontrol functions to run and regulate the various process activities(e.g., starting or stopping process machines, running process steps,controlling throughputs, etc.) that are needed to complete the job orderor at least that step of the manufacturing process associated with thejob order. If needed, the materials output by a particular stage or stepof a manufacturing process may be provided with a new RFID tag toidentify the existence of these materials in the plant as intermediateproducts. The command system 12 then tracks and may direct the movementof the generated material outputs (the intermediate products) to thenext stage in the manufacturing process 19 so as to be able to detectthese intermediate products as inputs to the next processing ormanufacturing stage.

Finally, in the shipping stage 21, completed outputs such as finishedgoods are tagged with new RFID tags or are otherwise associated withexisting RFID tags 22 and are held in a loading bay (or alternatively ina finished goods inventory or a staging area). To ensure proper deliveryto customers, the command system 12 matches the correct finished goodsand the correct shipping amount with that specified by a customershipping or purchase order (which may be part of a job order or jobnumber). The command system 12 then notifies the workers of the locationof the finished goods in the loading bay via information terminals(e.g., the computer stations 34, the PDAs 36 or headsets 38) so that thecorrect finished goods can be loaded and dispatched to the propercustomers. Additionally, the command system 12 may track movement of thefinished goods, via the RFID tags on the finished goods, to assure thatthe correct finished goods are provided to or placed into the correcttruck to assure proper delivery of the finished goods for a particularjob run or multiple job runs for a particular delivery. Moreover, insome cases, the command systems 12 may assure that the finished goodsare loaded into or on a truck (or railroad car, etc.) in a desired orderwhich will assure, for example, that the finished goods to be unloadedfirst from the truck are be placed in the back (rear) of the truck, forexample, while the goods to be unloaded last are placed in the front ofthe truck, for example (in a rear opening truck).

In any or all of these cases, access programming stored in the memory 26and executed on the processor 25, as well as, in some cases, the userinterface 29, the user interfaces 34, 36 and 38, the communicationmodule 33 and the control module 27 may act as or form parts of anaccess system that enables a user to access the location information forthe RFID tags as stored in the database 28 to affect the inventory ormanufacturing process in any of the manners described herein.

FIG. 2 illustrates an example corrugated packaging plant 50 that usesthe inventory and process management system 10 to manage a manufacturingprocess that produces corrugated packaging products. While FIG. 2describes a corrugated packaging plant, the inventory and processmanagement system 10 in general may be employed in any type ofmanufacturing process or plant used in the paper industry or outside ofthe paper industry. The manufacturing process in the corrugated plant 50is carried out in different areas of the plant 50 including a rollstockarea 52, a corrugator area 54 with a wet end area 54 a, a work inprocess (WIP) area 56, finishing areas 58 to 61, and a loading bay area62. A phased array antenna network 64 is deployed in the plant 50 by,for example, being hung from the ceiling of the corrugated plant 50 toenable the tracking of the location and movement of RFID taggedmaterials and goods within the plant 50. While FIG. 2 illustrates theantenna network 64 as having nine beam steerable phased array antennasystems 14 arranged in a 3×3 grid layout, the antenna network 64 ingeneral may have any number of antenna systems (phased array orotherwise) arranged in any type of layout or configuration.

Generally speaking, a controller associated with the phased arrayantenna network 64 is used to electronically steer an energy beamemanated from each of the phased array antennas 14 or to use atriangulation technique on signals from multiple antennas 14 tocontinuously sweep or scan over an area or volume of the plant floor tothereby provide real-time 3D detection, monitoring and tracking of RFIDtagged objects. In particular, during each scan or sweep of an antennathrough an area or volume of the plant covered by that antenna, the RFIDdetection system (that is part of the command system 12) connected tothe antenna network 64 may detect each and every RFID disposed withinthe swept area in a very precise manner (i.e., including very precise xand y horizontal coordinates and in many cases precise z verticalcoordinates) and may store the location of each such RFID tag asdetected during the scan or sweep. Additionally or alternatively, thephase array antennas 14 may be configured to provide only 2D detection.For example, to speed up processing speeds, the antennas 14 may beconfigured in a 2D mode to monitor movements in and out of trafficaisles. Moreover, the RFID detection system may detect movement of RFIDtags from scan to scan by comparing the current location of the RFID toits previous location. In this manner, the RFID detection system maytrack the movement of or follow the location of a particular RFID at anytime within the plant 50. If desired, the RFID detection system maystore a track or a path associated with each RFID tag over time.Moreover, the RFID system may cause each of the separate antennas of thenetwork 64 to periodically scan or sweep over the various locations orregions of the plant 50 at which RFID tags may be located, which mayinclude the entire plant 50, or only certain portions of the plant 50.If desired, the RFID system may scan or sweep over certain plantlocations, for example, locations at which RFID tags are likely to movemore often or more quickly, such as on the plant floor, in themanufacturing areas of the plant, in the loading bay of the plant, etc.,more often or at a higher periodic rate than the RFID system sweeps overother plant locations, for example, locations at which RFID tags arelikely to move less often, such as in the inventory storage areas of theplant. Of course, the periodic rate at which the RFID system scan orsweeps over any particular portion of the plant 50 may be set based onthe likely speed of movement of RFID tags through that location and thegranularity or detection accuracy needed for particular functions to beimplemented within the plant based on RFID tracking.

The details of the manner in which the RFID detection and trackingsystem operate to perform 3D RFID detection by creating and manipulatingone or more detection beams using the phased array antenna system 64 andthen periodically sweeping those beams over various areas of the plant50 to perform real-time 3D RFID detection at any location swept by thebeam is described in more detail in U.S. Patent Application PublicationNo. 2010/0207738 and so will not be described in detail herein. In anyevent, by continuously performing beam sweeping and RFID detection andupdating, the RFID system may detect and track the location of any RFIDtag in the plant 50 at any desired time. In other words, by periodicallysweeping over an area or volume in the plant using one or more of theantennas of the antenna system 64, the phased array antenna network 64employs a zonal monitoring approach that does not rely on the movementof the RFID tagged objects through a fixed portal or a read node (i.e.,stationary RFID readers) and that does not rely on the manual scanningof the RFID tagged objects (i.e., hand-held RFID readers) in order toachieve reliable RFID tag identification and/or to ascertain thelocation of the tagged objects. Thus, unlike conventional RFID systems,the phased array antenna network 64 can be used to track and monitor thelocation and movement of tagged materials and goods throughout thecorrugated plant 50 at any time, thereby enabling the command system 12to be able to perform various inventory and manufacturing processcontrol and management functions such as inventory management, processflow management and shipping management more effectively andefficiently.

Generally speaking, to perform the manufacturing tracking, control andmanagement functions described herein, the command system 12 stores arecord for each RFID tag in the system with each such record includingthe RFID tag number (i.e., a unique number or identification associatedwith the RFID tag) and various information about the material to whichthe tag is attached or with which the tag is associated. This inventoryor manufacturing information may include a type of product or material,a manufacturer of the product or material, characteristics of theproduct or material (e.g., a type of paint, paper, printing head, etc.)a quantity of the material (e.g., the amount of paper left on a paperroll to which the tag is attached, the amount of ink in a can or bucketto which the tag is attached, etc.), and other types of information.Moreover, if desired, each record may store a current location of theRFID tag within the plant and such locations may be identified in anydesired manner. For example, locations stored within these records maybe GPS locations or coordinates, may indicate an area or region orsub-region of the plant or a specific location in the plant, etc. thatis defined by the plant operator, or may be any other type of locationdesignation used in the plant. The command system 12 may then use theseRFID records (the locations of which are being constantly updated by theRFID detection and tracking system) to perform various process,inventory and shipping management or control functions as described inmore detail below.

As one example, inventory management is carried out by the commandsystem 12 in the rollstock area 52, where raw materials such as rolls ofpaper material are received and tagged with RFID tags for cataloging ina rollstock inventory. Of course, the rolls may have an RFID tagassociated therewith or applied thereto when these rolls arrive at theplant 50. In this case, a user or personnel at the plant may apply oraffix an RFID tag to the roll or other raw material and provideinformation to the command system 12 so as to the identity of thematerial (e.g., material type, manufacturer, material quantity, etc.) tobe stored as inventory item information in the record for the RFID tag(and its associated identification number) applied to the material. Aseach roll is placed into the rollstock inventory, the command system 12may use a tracking controller to track and record the location of eachroll in the electronic record of the RFID tag attached to the roll.However, to do this, the RFID system may simply scan the inventory bayperiodically and detect the current location of each RFID tag for whicha record exists in that area and then update the location fields for theelectronic records for those RFID tags.

When a job order or production run designed to produce a particularproduct is started or implemented within the plant, the command system12 begins to track or manage that job order using the RFID tags withinthe plant to assure that the correct raw materials are used in theproduction run for the job order, to assure that intermediate materialscreated during the manufacturing steps for the production run for thejob order are provided to the correct or to the appropriate machinesduring the production run when creating the final product, that themachines used to implement the production run for the job order have thecorrect raw materials (e.g., paper, ink, glue, etc.) provided thereto,equipment (printing plates, etc.) installed thereon, and programming(e.g., printing procedures, banding procedures, etc.) installed orloaded therein, etc. an for assuring that the correct final products areproduced and shipped to the customer as called for by the job order orjob number.

In the inventory control area, the command system 12, when tracking orimplementing a job order, may notify workers which roll or rolls need tobe acquired for transfer to the wet end area 54 a for the job order andwhere the rolls are located in the rollstock inventory (e.g., the bayand bin numbers at which the rolls for the job order are located). Asthe workers pick up the roll and leave the rollstock area 52, thecommand system 12 can detect movement of the roll via the RFID tagrecords and can verify that the correct roll is leaving or is beingtransported on the forklift, for example. If the wrong roll is picked upby mistake, then the command system 12 may alert the worker (via a headset, PDA, etc.) to go back and pick up the correct roll. Of course, oncean RFID tag is placed on a roll and is entered into or recognized by theRFID system, no other manual tracking activities (such as bar codescanning) needs to take place to perform this tracking.

As a further example, the command system 12 may operate to detect andtrack rolls in the wet end area 54 a and may detect and indicate whetherthe correct roll is placed onto the correct roll input or feeder at thewet end of the corrugator machine. Again, the command system 12 maydetect an improper roll (for the job to be run on the corrugatormachine) being loaded onto a roll feeder of the machine and may notifythe operator as such. Additionally, if desired, the command system 12may send or cause a halt or an interrupt signal to be sent to thecorrugator machine (or to the control system controlling the operationof the corrugator machine) to prevent operation of the corrugatormachine until the correct roll is loaded onto the feeder. Alternatively,the command system 12 may send an enable signal to enable the operationof the production equipment only when the correct materials are in placefor the job order being implemented or run on the equipment. Inaddition, the command system 12 may determine or calculate how muchpaper material is used or is removed from the roll (e.g., by trackingthe amount of paper used in the corrugator machine) for the job orderand thus may calculate the remaining length or amount of paper on theroll and store this length or amount in the electronic record for theRFID tag on the paper roll when the roll is removed from the corrugatormachine. The command system 12 may perform this record keepingautomatically in order to prevent inventory stockouts and in order toreorder new stock if needed. Moreover, this paper amount, which may bestored in the record for the RFID tag on the roll, may be used in futureoperations to determine if this roll has enough paper to fulfill afuture job order that may use that type of paper. On the other hand,once the job order is completed, any roll with leftover paper materialmay be tagged with a new RFID tag so that the unfinished roll can beidentified and located by the command system 12 for use in future joborders, thereby eliminating waste and reducing cost in the rollstockinventory.

As another example, the command system 12 performs process flowmanagement in the corrugator area 54, the WIP area 56, and the finishingareas 58 to 61 by detecting the movement of tagged materials in theseareas. As intermediate products such as stacks of corrugated sheets comeoff a corrugator machine in the corrugator area 54, RFID tags may beattached to each sheet of paper or to one of the sheets of paper in aparticular stack of corrugated paper for identification and tracking bythe command system 12. In another case, an RFID tag may be applied to acart or pallet onto which the stacks of paper from the corrugatormachine are placed. In some scenarios, individual sheets may be taggedand processed in which case the RFID tags are attached to individualsheets instead of stacks. The tagged stacks (or paper) may be registeredwith the command system 12 by having an RFID tag attached thereto and anelectronic record created for the RFID tag indicating, for example, thejob order or job number for which the stack of corrugated paper wascreated, the identity or nature of the corrugated stack of paper or anyother desirable information. The tagged stack of corrugated paper maythen be moved to or placed in the WIP area 56 until needed for furtherprocessing. The command system 12 determines from the job order whichstack needs to be processed and proceeds to send the correct stack toone of the four finishing areas 58 to 61, either by communicating with aconveyor belt controller to cause the controller to automatically movethe stack on a conveyor belt or by notifying workers to manually movethe stack. If the workers move the wrong stack by mistake, then thecommand system 12 may detect the presence of the tagged stack in thewrong area of the process plant (or the presence of an incorrect stackat the input of the machine used for the next stage of production) andalert the workers to go back and move the correct stack to the input.

In some embodiments, different finishing areas may convert thecorrugated sheets into different corrugated packaging products. Forexample, the finishing areas 58 and 59 may convert the sheets into boxeswhereas the finishing areas 60 and 61 may convert the sheets intopoint-of-purchase displays. In other embodiments, all finishing areasmay convert the corrugated sheets into one type of product. For example,the finishing areas 58 to 61 may convert the sheets into only boxes orpoint-of-purchase displays. Depending on the scenario/embodiment, thecommand system 12 may determine the appropriate finishing area for thestack based on the job order. Once the stack is in one of the finishingareas 58 to 61, the command system 12 determines required processoperations (e.g., folding, gluing, die-cutting, printing, banding, etc.)to be performed in the finishing area to convert the stack of corrugatedsheets into finished goods (e.g., boxes, point-of-purchase displays,etc.). In addition, for operations such as printing, the command system12 may determine various process supplies that are required for theoperations performed by the various machines in the plant such aspaints, inks, printing plates, glues, etc. These process supplies mayalso be tagged with RFID tags which allow the command system 12 to trackand identify which process supplies or plant machine parts are neededfor or should be used in a production run for a particular job order orjob number. The command system 12 may notify workers to find andassemble the correct process supplies from a process supplies inventory.These actions may include loading or installing the supplies on thecorrect machine, such as installing dyes on cutting or manufacturingmachines, installing printing plates on a printing device, installingpaint or ink buckets or cartridges on a printing machine, loading glueinto a machine, etc. If the wrong process supplies are assembled or areinstalled on a machine by mistake, then the command system 12 may detectthe presence of the materials having the RFID tags not appropriate forthe production run at the locations of the machines to be used for theproduction run and alert the workers and/or suspend or interrupt theoperation of the process (e.g., by automatically halting the operationof the machine) until the workers have found and assembled or installedthe correct process supplies. Conversely, the command system 12 mayassure that all of the correct materials for a production run for aparticular job number by determining that the RFID tags for the correctmaterials are present at the machines to perform the production run, andthen alert workers or halt operations via a controller when some productor material needed for the production run is missing.

When the correct process supplies are in place, the command system 12may operate or enable process controllers to run process machines andregulate the various process operations needed to generate the desiredfinished goods by sending enable signals to the controllers for thosemachines. The finished goods are then tagged with RFID tags for furtheridentification and tracking by the command system 12. In some cases, thesame RFID tag as applied to the corrugated sheets may be used toidentify the finished goods made from the corrugated sheets. In othercases, new RFID tags may be applied to the finished goods, or to acontainer or cart on which the finished goods are placed to track thefinished goods.

Moreover, as the tagged finished goods approach banding machines nearthe end of the finishing areas 58 to 61, the command system 12 maydetermine which banding sequence to use for this set of finished goodsbased on the job number and may direct the banding machines to deploythe correct banding sequence so that the finished goods are properlybanded for dispatch. In this case, the command system 12 may tell theoperator of the banding machine which sequence to use, may automaticallyinstall or download the correct banding sequence to the banding machine,etc. In some cases, the command system 12 may simply detect the bandingsequence that a banding machine is set to use and may halt or interruptthe operation of the machine until the correct banding sequence isinstalled on the banding machine for the finished goods that areapproaching or that are at the input of the banding machine as detectedby the command system using the RFID tags on the finished goods. In anyor all of these cases, the command system 12 may notify a worker oroperator that the incorrect banding sequence is programmed into thebanding machine or may instruct the operator or worker as to the correctsequence to use for this set of finished goods.

As a further example, shipping management is handled by the commandsystem 12 in the loading bay area 62, where the tagged and properlybanded finished goods are held for delivery to customers. When acustomer shipping order is ready, the command system 12 notifies workerswhich finished goods to acquire, the amount of finished goods to ship,where the finished goods are located in the loading bay, and whichloading bay door to use. If the wrong finished goods or the wrong amountof finished goods are acquired or loaded by mistake as detected by themovement of the RFID tags for the goods being loaded onto trucks, thenthe command system 12 alerts the workers to go back and obtain thecorrect finished goods or the correct amount of finished goods until thecustomer shipping order is properly fulfilled. In addition, the commandsystem 12 may instruct the workers to load a truck, via one of theshipping bays, in a particular order to make loading or unloading of thetruck more efficient. Of course, in any of these cases, the system 12may interface with the user via visual displays, such as lights thatchange color to indicate an error or correct operation, via a displayinterface such as a PDA, a monitor in the area, etc., via a tactileinterface, which may vibrate in various different manners to indicateproper or improper operation or actions, or via audio interfaces inwhich the system 12 may send an audio signal, which may be an alarm oralert signal, such as a beeping or klaxon sound, or a speech signal orany other type of audio signal, to be played to the user via a speaker,such as a headset worn by the user.

FIG. 3 depicts various materials, goods, or equipment in the corrugatedplant 50 that may be tagged with the RFID tags 22. These materials,goods or equipment include, as examples only, raw materials such as aroll of paper material 70; intermediate products such as individualcorrugated sheets 72 or a stack of corrugated sheets 74; equipment suchas a trolley or cart or pallet 76 carrying a stack of corrugated sheets;process supplies such as a paint supply 78, a printing plate or a dye orany other machine tool 80, or an ink supply cartridge 82; and finishedgoods such as individual corrugated boxes 84 or a pallet of bandedcorrugated boxes 86.

Generally speaking, the RFID tags 22 may be any passive or batteryassisted passive (BAP) ultra-high frequency RFID tags, which do not havetheir own power source but instead are excited by energy received from areader (e.g., the energy beam from the phased array antenna system 64).The passive and BAP RFID tags respond to the reader by modulating dataonto some of the received energy and then reradiating the energy back tothe reader (the phased array antennas in this case) which in turndecodes the data. Typically, the encoded data will be the RFID tagnumber, but other data could be encoded or used instead or as well.

FIG. 3 also illustrates an example data structure or electronic record92 for the RFID tags 22, wherein the record 92, in this case, includesone or more data fields 93 for identifying and locating tagged objects.With reference to FIG. 3, the data structure 92 includes a tag numberfield 95, a type field 96, a property field 97, a location field 98, anda job number field 99. The tag number field 95 provides a uniqueidentifier for a tag to be stored and categorized in a database. Thetype field 97 indicates the type of material to which the tag isattached. For example, if the tag is attached to the roll of papermaterial 70, then the type field may indicate a ‘roll’, whereas if thetag is attached to the stack of corrugated sheets 74, then the typefield may indicate a ‘stack’. The type field for a particular RFID tagmay change as the material to which the tag is attached or with whichthe tag is associated changes within the process, e.g., from a stack ofcorrugated sheets, to a stack of cut box blanks, to a stack or group ofprinted boxes, to a set of finished goods in the form of a banded stackor group of printed boxes. The property field 97 describes properties orcharacteristics associated with the type of material indicated in thefield 96. For example, for the roll of paper material 70, the propertyfield 97 may indicate the length of the roll or other information thatdescribes the characteristics of the roll. For the stack of corrugatedsheets 74, the property field 97 may indicate the number of sheets inthe stack or other information that describes the characteristics of thestack or of the sheets within the stack. Generally speaking, thisinformation may be inventory or material item information that definesthe property of the materials. The location field 98 includes locationcoordinates or other location information for the tag (e.g., location ofthe tag in the corrugated plant 50) so that the tag can be located andtracked.

Still further, each RFID tag record 92 may include the job number field99 that stores or indicates the job number to which the RFID tag iscurrently tied or with which the RFID tag is associated. In some cases,the job number field 99 will be unassigned or blank, such as in the caseof RFID tags on paper rolls stored in inventory, printing plates,buckets of paint or ink in storage, etc. However, other RFID tag records92 may have a job number assigned thereto at the time that the RFID tagis first registered and this job number may remain constant, such aswhen an RFID tag is applied to the stack of corrugated paper produced bythe corrugator machine and then becomes associated with box blanks forthe job number and then becomes associated with printed boxes for thejob number and then becomes associated with finished goods for the jobnumber. In these cases, the RFID tag may be associated with materialsthat are uniquely tied to (created for) that job number. In still othercases, RFID tags may have job numbers temporarily assigned thereto, suchas the case of an ink or paint bucket, or a printing plate, which mayhave a job number assigned thereto only while that material is beingused on or in a machine or processing step that is performing steps forthe job number. At other times, the job number may be unassigned.Although the data structure 92 in FIG. 3 is illustrated as having fivedata fields, the data structure 92 in general may have any number ofdata fields to identify and located tagged objects.

FIG. 4 represents an example manufacturing process being carried out inthe different areas of the corrugated plant 50 (FIG. 2) including thecorrugator area 54, the WIP area 56, the finishing areas 58 to 61, andthe loading bay area 62, in which RFID tags (e.g., the RFID tags 22 ofFIG. 3) may be attached to materials and the electronic records thereofmay be used to identify and track various materials and goods in orderto control or manage the process flow in the example manufacturingprocess. For example, as illustrated in FIG. 4, an RFID tag 100 with anassociated data structure 102 is attached to a roll of paper material104, an RFID tag 106 with an associated data structure 108 is attachedto a stack of corrugated sheets 110, and an RFID tag 112 with anassociated data structure 114 is attached to a pallet of bandedcorrugated boxes 116. By attaching the tag 100 to the roll 104, the roll104 can be identified and located in a rollstock inventory area (e.g.,the rollstock area 52 in FIG. 2), and when needed, be brought to thecorrugator area 54 for further processing. Similarly, by attaching thetag 106 to the stack 110, the stack 110 can be identified and tracked inthe WIP area, and when needed, be directed to one of the finishing areas58 to 61 for further processing. Furthermore, by attaching the tag 112to the pallet 116, the pallet 116 can be monitored in the loading bayarea 62, and when needed, be located and loaded onto delivery trucks 118to 120 for dispatch to customers.

RFID tags attached to different objects may have data structures thatstore different data to identify and locate the objects. For example,the data structure 102 associated with the tag 100 has four data fieldsincluding a tag number field 122 that identifies the tag 100, a typefield 123 that indicates the tag 100 is attached to a roll such as theroll 104, a length field 124 that describes the length of the roll 104,and a location field 125 that indicates the location of the roll 104 inthe corrugated plant 50. The command system 12 may update the lengthfield 124 to reflect any changes in the roll length and thus the lengthof the roll 104 changes when a quantity of the roll material 126 is usedin the corrugator area 54. The command system 12 updates the locationfield 125 whenever the roll 104 is moved in the rollstock inventory areaor transported to and from the corrugator area 54. By tracking thelocation and movement of the roll 104, the roll 104 can be properlyprocessed in the corrugated plant 50. While the embodiment of the datastructure 102 in FIG. 4 is shown with four data fields, in otherembodiments, the data structure 102 may have any number of data fieldsto identify and locate the roll 104.

In another example, the data structure 108 associated with the tag 106has six data fields including a tag number field 128 that identifies thetag 106, a type field 129 that indicates the tag 106 is attached to astack of corrugated sheets such as the stack 110, a number of sheetsfield 130 that describes the number of corrugated sheets in the stack110, a location field 131 that indicates the location of the stack 110,a job order number field 132 that associates the stack 110 to a joborder or production run, and a destination field 133 that shows wherethe stack 110 should be moved to in the corrugated plant 50. The numberof sheets field 130 is useful when verifying if sheets are missing fromthe stack. The location field 131 is useful for tracking the locationand movement of the stack 110, either when the stack is being held inthe WIP area or when the stack is being transferred to the finishingareas 58 to 61 for processing. The job order number field 132 allows thestack 110 to be processed in accordance with the proper job order and tobe associated with a job order number for identification, while thedestination field 133 allows the stack 110 to be moved to a properstaging area in the WIP area 56 and/or one of the proper finishing areas58 to 61 to complete the processing required for the job order. Whilethe embodiment of the data structure 108 in FIG. 4 is shown with sixdata fields, in other embodiments, the data structure 108 may have anynumber of data fields to identify and locate the stack 110.

In a further example, the data structure 114 associated with the tag 112has six data fields including a tag number field 134 that identifies thetag 116, a type field 135 that indicates the tag 112 is attached to apallet of banded corrugated boxes such as the pallet 116, a number ofboxes field 136 that describes the number of corrugated boxes on thepallet 116, a location field 137 that indicates the location of thepallet 116, a shipping order number field 138 that associates the pallet116 to a customer shipping order (which may be associated with a jobnumber), and a destination field 139 that shows the destination to whichthe pallet 116 should be shipped. The number of boxes field 136 is usedby workers to verify the correct amount of boxes to be shipped againstwhat is required in the customer shipping order. The location field 137is used for tracking the location and movement of the pallet 116 in theloading bay area 62 and onto one of the delivery trucks 118 to 120. Theshipping order number field 138 along with the destination field 139allow the pallet 116 to be matched to correct customers and properlydispatched for delivery. Shipping order numbers may be tied to job ordernumbers in some cases, and may, in fact, be the job order number. Whilethe embodiment of the data structure 114 in FIG. 4 is shown with sixdata fields, in other embodiments, the data structure 114 may have anynumber of data fields to identify and locate the pallet 116.

FIG. 5 illustrates an example rollstock inventory area 145 in acorrugated plant (e.g., the rollstock area 52 in the corrugated plant 50in FIG. 2), in which the location and movement of rolls of papermaterial are monitored in an example application 147 communicating withan inventory database 149. The rollstock inventory 145 includes adelivery truck 152 loaded with one or more untagged rolls of papermaterial 154, a received tagged roll 156, a storage facility 158 havingstorage compartments 158 a to 158 d, each storing one or more taggedrolls 159, and a trolley or forklift carrying a tagged roll 160. Asindicated in FIG. 5, the untagged rolls of paper material 154 from thedelivery truck 152 are first received and tagged with the RFID tags 22,before being placed in one of the compartments 158 a to 158 d in thestorage facility 158. For example the received roll 156 is tagged beforebeing placed in storage compartment 158 c. At the time of tagging,various fields of the electronic record for the RFID tag may be filledout and stored by or within the command system 12 (FIG. 1) to associatethe RFID tag with the paper roll (e.g., type, manufacturer, length,etc.). The command system 12 may then detect movement of the RFID tag(using the RFID detection and tracking system described herein) and thustrack and store the physical storage location of each tagged roll in theinventory database 149 so that each tagged roll can be located in thestorage facility 158 and picked up for subsequent further processing oruse.

With reference to FIG. 1, the application 147 may be stored in thememory 26, and executed by the processor 25 of the command system 12.The application 147 may be executed to display an image of the storagefacility 158 along with the locations of the RFID tagged rolls in therollstock inventory 145. Movements of the tagged rolls in (e.g., thereceived roll 156 going into the storage compartment 158 c), and out(e.g., the trolley carrying a tagged roll 61 out of the storagecompartment 158 d) of the storage facility 158 are shown as dashed lines163 in the application 147 to provide real-time monitoring of therollstock inventory 145.

Generally speaking, before the start of a job order or production run,order information is obtained from customers regarding the desirednumber and type of product to be made, as well as product specificationsdescribing the materials to use, the dimensions of the product,appearances, and other product related information. Upon receiving theorder information, workers search through a job order recipe database todetermine if a recipe exists for the desired product. If a match isfound, then the corresponding recipe or production run may be used as atemplate for the current job order. The template recipe includes a listof required inputs, required number of manufacturing stages, andrequired inputs needed at each manufacturing stage in order to producethe finished product. The template recipe also includes a list ofintermediate products generated during a manufacturing process, whichmay be used as inputs to some intermediate manufacturing stages. Ofcourse, modifications can be made to tailor the template recipe tosatisfy current needs. For example, if the desired product is to bepainted or printed with a different color than the recipe calls for,then the template recipe may be modified to use a different paint or inkcolor during the painting or inking stage of the manufacturing process.If the workers cannot find an existing recipe in the job order recipedatabase, then a new recipe may be created in the database for thecurrent job order. The workers will use the order information to definea list of required inputs or materials, required number of manufacturingstages, and any intermediate products that may be generated and usedduring the manufacturing process. The new recipe for the desired productmay also be created by importing and modifying information stored in anexisting recipe for a similar product that had been made before. Oncethe new recipe is created or if a template recipe is selected, a joborder number is assigned to identify the recipe and the job order.

The workers then enter a job order number into a command system 12 tocommence the job order run or in conjunction with commencing aproduction run for the job order or job number. Alternatively, thecommand system may automatically load the job order number. The commandsystem 12 or applications executed by the command system 12 generates orobtains a process flow chart by referencing information in the job orderrecipe. The flow chart describes the flow of inputs and outputs to andfrom each manufacturing stage for the job number. By following the flowchart from start to finish, the command system 12 can control or managethe overall process flow in the manufacturing process for the productionrun or production runs for the job order. For example, at the beginningof the flow chart, the required inputs for the first manufacturing stageare raw materials stored in an inventory. The type of raw materialsneeded in the first manufacturing stage is determined from the job orderrecipe. The command system 12 searches an inventory database to findRFID tags associated with the required raw materials for the job order.Once the required raw materials are found in the inventory (and the RFIDtags associated with these materials are determined), the command systemuses the RFID tags attached to the raw materials to manage theproduction run. By identifying the RFID tag attached to the rawmaterials, the location of the raw materials in the inventory can bedetermined and tracked. Thus, the command system 12 can direct workersto acquire and transfer the needed raw materials from the inventory tothe first manufacturing stage by monitoring the movement of the RFIDtagged raw materials determined to be used for this production run. Oncethe location of the raw materials is ascertained to be in the correctplace on or at the manufacturing equipment, the command system 12 canproceed to run the manufacturing stage or allow the manufacturing stageto be run by, for example, operating or enabling the process controllersto execute various process activities that are needed to convert the rawmaterials into intermediate products. As noted above, RFID tags may beattached to the intermediate products such that the command system 12can track the location and movement of the intermediate products, whileat the same time, associate the intermediate products to the job orderfor further processing.

As the command system 12 proceeds down the flow chart, the requiredinputs to the subsequent manufacturing stages are determined from thejob order recipe. The required inputs may be intermediate productsproduced from a previous manufacturing stage, and/or process suppliesneeded to run process activities in the next manufacturing stages. Byaccessing the electronic record for the RFID tag attached to theintermediate products, the intermediate products can be associated tothe correct job order number and thus moved to the appropriatemanufacturing stages to ensure a proper process flow in the job order.Additionally, the type of process supplies needed is also determinedfrom the job order recipe. In this case, the command system 12 searchesa process supplies database to find the required process supplies neededfor a production run for the job order or job number. Once the requiredprocess supplies are found, the command system 12 identifies the RFIDtag (through the RFID tag number) attached to the process supplies andtracks or determines the location of the process supplies in a processsupplies inventory. The command system 12 can then direct workers toacquire, transfer and install the needed process supplies in theappropriate manufacturing stages before running the manufacturing stagesto produce more intermediate products or generate the desired finishedproducts.

Of course, at any time, a new RFID tag may be attached to or associatedwith products produced at any production stage, or an existing RFID tagmay be updated to track the location and associate the newly producedintermediate products and/or finished products to the job order forfurther processing or use. When the command system 12 reaches the end ofthe production flow chart, the job order is complete (that is, thefinished products are now prepared) and the job order number may bematched to a customer shipping order for delivery to the propercustomer(s).

FIG. 6 illustrates an example manufacturing process 165 in a corrugatedplant (e.g., the corrugated plant 50 in FIG. 2), in which the flow ofRFID tagged inputs and outputs is monitored in an example application167 communicating with a job order recipe database 170, an inventorydatabase 171, and a process supplies database 172, to control theprocess flow in the manufacturing process 165. The manufacturing process165 includes one or more manufacturing stages or regions such as amanufacturing stage 175 which may represent the corrugator area 54 inFIG. 2, and a manufacturing stage 177 which may represent one of thefinishing areas 58-61 in FIG. 2, and various inputs such as a roll ofpaper material 180, a printing plate 182, and a paint supply 184, andoutputs such as a stack of corrugated sheets 186, and a corrugated box188 (which could also be a stack or group of corrugated boxes). Some ofthe outputs may also be used as inputs in the manufacturing process. Forexample, the output generated from the manufacturing stage 175 (i.e.,the stack of corrugated sheets 186) is fed into the manufacturing stage177 as an input. The inputs and outputs in each manufacturing area aretagged with the RFID tags 22, which allow the location and movement ofthe inputs and outputs to be tracked and directed so as to control theoverall process flow in the manufacturing process 165.

The application 167 may be stored in the memory 26 of FIG. 1 forexample, and executed by the processor 25 of the command system 12 inFIG. 1. With reference to FIG. 6, the application 167 displays a processflow chart 190 of the manufacturing process 165, which includes a joborder block 192, an input block 194, a manufacturing block 196, anoutput/input block 198, a manufacturing block 200 having an input block201, and an output block 204.

The process flow chart 190 is generated when a job order number isentered or received by the application 167 to run a production run for ajob order. The application 167 first searches the job order recipedatabase 170 to retrieve the job order recipe associated with the joborder number, which may be created by workers as described earlier. Theapplication 167 then proceeds to build or implement the flow chart 190using information from the job order recipe such as the required inputs(e.g., the roll 180, the printing plate 182, the paint supply 184) foreach required manufacturing stages (e.g., manufacturing stages 175 and177), the manufacturing stages to implement, the programming orsequences to be implemented at the process stages (e.g., the bandingsequence to use at a banding machine, etc.). Once the flow chart 190 isgenerated, the application 167 proceeds to run the job orderautomatically by executing the flow chart 190. Alternatively, workersmay execute the flow chart 190 manually if desired. In anotherembodiment, the flow chart 190 describes programming performed by theprocessor to implement the application 167.

The job order starts at the job order block 192, which shows the joborder number that identifies the current job order. Next, the inputblock 194 may indicate the roll 180 as the required input to themanufacturing block 196 (i.e., the manufacturing stage 175). Theapplication 167 accesses the inventory database 171 to search for theroll 180. Once, the roll 180 is found in the inventory database 171, theRFID tag associated with the roll 180 is identified (through the RFIDtag number) so that the application 167 can track or determine thephysical location of the roll and direct workers to pick up and transferthe roll to the machine used in the manufacturing stage 175. Theapplication 167 will not execute the flow chart 190 further to run thejob order until the roll 180 is properly acquired and staged at thecorrect location on the manufacturing equipment. When the roll 180 isascertained to be in the correct location for implementing the currentmanufacturing stage, as determined by the RFID tracking system which maymonitor the movement of the RFID tagged roll from the inventory to themanufacturing stage 175, the application 167 executes the manufacturingblock 196 to process the roll by for example, operating processcontrollers in the manufacturing stage 175 to run a corrugator machinethat converts the roll 180 into the stack 186. Of course, in this case,the application 167 may communicate with a controller of the machine toimplement the production step, or may remove an inhibit signal from thecontroller or may otherwise indicate to an operator that the productionstep can now be properly executed.

After execution of the first processing step in this case being thecorrugator machine, the output stack 186 is then shown in theoutput/input block 198 as the required input to the manufacturing block200 (i.e., the manufacturing stage 177). An RFID tag may be assigned tothe stack 186 to track the location and movement of the stack as well asassociate the stack to the current job order. Thus, the stack 186 can bedirected to or managed to be delivered to the manufacturing stage 177for further processing. From the job order recipe, other inputs, forexample process supplies such as the printing plate 182 and the paintsupply 184, that required for the manufacturing block 200 are determinedand are shown in the input block 201. The application 167 then accessesthe process supplies database 172 to search for a printing plate 182 andthe paint supply 184 in a storage inventory needed for the productionrun for this job number and may determine the RFID tag associated withthese materials. Once the those process supplies are determined in theprocess supplies database 172, the RFID tags attached to the printingplate 182 and the paint supply 184 are identified (through the RFID tagnumbers) so that the application 167 can direct workers to locate,transfer and install the printing plate 182 and the paint supply 184 inthe appropriate process machines (e.g., printing machines) inmanufacturing stage 177. The application 167 will not execute the flowchart 190 further to run the job order until the stack 186, the printingplate 182, and the paint supply 184 are in the correct locations in themanufacturing stage 177. Alternatively, the application 167 may detectif RFID tags for the correct materials (printing plate, ink, etc.) arepresent at or on the printing machine already and, if so, may enable themachine to operate. In general, the application 167 determines if theproper materials are at the proper location or directs these materialsto the proper locations by tracking the location and directing themovement of the stack 186, the printing plate 182, and the paint supply184 through their attached RFID tags. Once all of the required inputsare in place, the application 167 can proceed to execute themanufacturing block 200 by for example, operating process controllers inthe manufacturing stage 177 to run a folder and gluer machine, aprinting machine and other equipment needed to produce the box 188. Thegenerated box 188 is then shown in the output block 204. At this point,an RFID tag may be assigned to the box 188, which can be used toassociate the box 188 to the current job order and to locate andtransfer the box (through the RFID tag number) to other manufacturingstages in the manufacturing process 165 for further processing or use.If desired, the same RFID tag that was used on the corrugated sheetsprovided to this stage may be updated (i.e., the record of which may beupdated) to reflect that this RFID tag is now associated with printedboxes (made from the corrugated sheets). The application 167 maycontinue to perform these operations at each manufacturing stage (e.g.,the banding stage, and other manufacturing stage) until the set offinished goods for the job order or job number are completed or aremade.

FIG. 7 depicts an example flow diagram of a method 210 that may beimplemented to manage a manufacturing process by tracking andcontrolling the flow of RFID tagged inputs and outputs. With referenceto FIG. 1, the method 210 may be implemented by one or more computerimplemented routines or programs or modules stored in the memory 26, andexecuted by the processor 25 of the command system 12.

At a block 212, the method 210 receives a job order number to start ajob order or production run in the manufacturing process. The method 210uses the job order number to obtain a job order recipe, which may becreated beforehand either from presorted instructions or routines orbased on user input, from a database (e.g., the job order recipedatabase 170). From the job order recipe, the method determines therequired inputs and the required type and number of manufacturing stagesthat are needed to produce the desired outputs for the job order. At ablock 214, the method searches through other databases (e.g., theinventory database 171, the process supplies database 172) to find therequired inputs (e.g., raw materials, process supplies). Once the inputsare located in the databases, the system determines the RFID tagsassociated with the inputs needed for the various manufacturing stagesof the production run, and may begin tracking these RFID tags to performprocess management of the production run for the job order. For example,if the required inputs are raw materials for the first manufacturingstage, then the raw materials are located in an inventory through theattached RFID tag and moved from the inventory to the firstmanufacturing stage. If the required inputs are intermediate outputsgenerated from a previous manufacturing stage, then the intermediateoutputs are located through the attached RFID tag and directed to movefrom the previous manufacturing stage to the next manufacturing stagefor further processing. Accurate process management of a production runfor a job order gives customers, especially in critical industries likemedical or food, complete traceability of where and how the product wasmade, which in turn helps to reduce a manufacturer's liability. At ablock 216, the command system 12 tracks movement of the inputs to thecorrect manufacturing stage by tracking the RFID tags attached to thedetermined inputs. At a block 218, the method 210 determines if thecorrect inputs are at the correct manufacturing stage. If the correctinputs are not in place, then the method 210 may notify a user oroperator or may take some other step, such as interrupting or haltingthe operation of the process machine to be used in this manufacturingstep for producing the job of the job order or notifying an operator,and returns control to the block 216 to continue tracking the RFID tags.If the correct material inputs are in place in the manufacturingprocess, then the method 210 runs or allows the manufacturing stage tobe run at a block 220 by for example, operating process controllers(e.g., the controllers 16 of FIG. 1) to execute and control variousprocess machines and process steps that are need to generate the desiredoutputs. Because the command system 12 can track the precise location ofthe RFID tags (typically to within one square foot or even eight inches)and associate the current job order to the inputs, only those RFIDtagged inputs with the proper job order number and placed at the correctplaces in the manufacturing stage are used. For example, RFID taggedobjects (e.g., other potential inputs such as generated intermediateoutputs from another job order) near the manufacturing stage will not beused because the objects are not associated with the current job order.Once the method 210 finishes running the manufacturing stage in block220, the generated outputs may tagged with other RFID tags in a block222 (or the records for the RFID tags used on the inputs to the previousmanufacturing stage are updated to reflect the new intermediate productor finished goods to which the tags are attached) so that the locationand movement of the outputs can be tracked and controlled to manage theoverall process flow in the manufacturing process.

At a block 224, the method 210 determines if the required number ofmanufacturing stages for the job order has been executed. If the lastmanufacturing stage has not been executed, then the method 210 returnsto the beginning of block 214 to continue determining the requiredinputs to run the remaining manufacturing stages. However, if the lastmanufacturing stage has been reached, then the tagged outputs areprepared for dispatch to customers. At block 226, the method 210 matchesthe outputs to a customer shipping order for proper loading and shippingto the correct customers. Once customer delivery is made, the job orderis complete. Of course, the method 210 returns to the block 212 to starta new job order at any time. Also, the method 210 may be halted for anyparticular job run and the method may be run simultaneously in the plantfor various different job order numbers.

Moreover, to manage shipping, the system may receive a shipping orderand use the RFID tracking system to track that the RFID tags on thefinished goods associated with the shipping order are placed on theproper truck (e.g., leave the plant via a particular loading bay doorwhich an operator may indicate as the location of the truck in which thefinished goods for this shipping order is parked). Likewise, as notedabove, the system may automatically produce a bill of landing indicatingor listing the finished goods that that were actually placed on thetruck as detected by the RFID tracking system and the records for theRFID tags that were detected as being placed on the truck. Stillfurther, the system may determine or manage the order in which variousdifferent finished goods are placed onto a truck so as to load the truckin a proper order when a single truck is being used to transport morethan one shipping order.

The following additional considerations apply to the foregoingdiscussion. Throughout this specification, plural instances mayimplement functions, routines, or operations structures described as asingle instance. Although individual functions and instructions of oneor more methods are illustrated and described as separate operations,one or more of the individual operations may be performed concurrently,and nothing requires that the operations be performed in the orderillustrated. Structures and functionality presented as separatecomponents in example configurations may be implemented as a combinedstructure or component. Similarly, structures and functionalitypresented as a single component may be implemented as separatecomponents. These and other variations, modifications, additions, andimprovements fall within the scope of the subject matter herein.

Additionally, certain embodiments are described herein as includinglogic or a number of functions, components, modules, blocks, ormechanisms. Functions may constitute either software modules (e.g.,non-transitory code stored on a tangible machine-readable storagemedium) or hardware modules. A hardware module is a tangible unitcapable of performing certain operations and may be configured orarranged in a certain manner. In example embodiments, one or morecomputer systems (e.g., a standalone, client or server computer system)or one or more hardware modules of a computer system (e.g., a processoror a group of processors) may be configured by software (e.g., anapplication or application portion) as a hardware module that operatesto perform certain operations as described herein.

In various embodiments, a hardware module may be implementedmechanically or electronically. For example, a hardware module mayinclude dedicated circuitry or logic that is permanently configured(e.g., as a special-purpose processor, such as a field programmable gatearray (FPGA) or an application-specific integrated circuit (ASIC)) toperform certain functions. A hardware module may also compriseprogrammable logic or circuitry (e.g., as encompassed within ageneral-purpose processor or other programmable processor) that istemporarily configured by software to perform certain operations. Itwill be appreciated that the decision to implement a hardware modulemechanically, in dedicated and permanently configured circuitry, or intemporarily configured circuitry (e.g., configured by software) may bedriven by cost and time considerations.

Accordingly, the term hardware should be understood to encompass atangible entity, be that an entity that is physically constructed,permanently configured (e.g., hardwired), or temporarily configured(e.g., programmed) to operate in a certain manner or to perform certainoperations described herein. Considering embodiments in which hardwaremodules are temporarily configured (e.g., programmed), each of thehardware modules need not be configured or instantiated at any oneinstance in time. For example, where the hardware modules comprise ageneral-purpose processor configured using software, the general-purposeprocessor may be configured as respective different hardware modules atdifferent times. Software may accordingly configure a processor, forexample, to constitute a particular hardware module at one instance oftime and to constitute a different hardware module at a differentinstance of time.

Hardware and software modules can provide information to, and receiveinformation from, other hardware and/or software modules. Accordingly,the described hardware modules may be regarded as being communicativelycoupled. Where multiple of such hardware or software modules existcontemporaneously, communications may be achieved through signaltransmission (e.g., over appropriate circuits and buses) that connectthe hardware or software modules. In embodiments in which multiplehardware modules or software are configured or instantiated at differenttimes, communications between such hardware or software modules may beachieved, for example, through the storage and retrieval of informationin memory structures to which the multiple hardware or software moduleshave access. For example, one hardware or software module may perform anoperation and store the output of that operation in a memory device towhich it is communicatively coupled. A further hardware or softwaremodule may then, at a later time, access the memory device to retrieveand process the stored output. Hardware and software modules may alsoinitiate communications with input or output devices, and can operate ona resource (e.g., a collection of information).

The various operations of example functions and methods described hereinmay be performed, at least partially, by one or more processors that aretemporarily configured (e.g., by software) or permanently configured toperform the relevant operations. Whether temporarily or permanentlyconfigured, such processors may constitute processor-implemented modulesthat operate to perform one or more operations or functions. The modulesreferred to herein may, in some example embodiments, compriseprocessor-implemented modules.

Similarly, the methods or functions described herein may be at leastpartially processor-implemented. For example, at least some of thefunctions of a method may be performed by one or processors orprocessor-implemented hardware modules. The performance of certain ofthe functions may be distributed among the one or more processors, notonly residing within a single machine, but deployed across a number ofmachines. In some example embodiments, the processor or processors maybe located in a single location (e.g., within a home environment, anoffice environment or as a server farm), while in other embodiments theprocessors may be distributed across a number of locations.

The one or more processors may also operate to support performance ofthe relevant operations in a “cloud computing” environment or as a“software as a service” (SaaS). For example, at least some of thefunctions may be performed by a group of computers (as examples ofmachines including processors), these operations being accessible via anetwork (e.g., the Internet) and via one or more appropriate interfaces(e.g., application program interfaces (APIs).

The performance of certain of the operations may be distributed amongthe one or more processors, not only residing within a single machine,but deployed across a number of machines. In some example embodiments,the one or more processors or processor-implemented modules may belocated in a single geographic location (e.g., within a homeenvironment, an office environment, or a server farm). In other exampleembodiments, the one or more processors or processor-implemented modulesmay be distributed across a number of geographic locations.

Some portions of this specification are presented in terms of algorithmsor symbolic representations of operations on data and data structuresstored as bits or binary digital signals within a machine memory (e.g.,a computer memory). These algorithms or symbolic representations areexamples of techniques used by those of ordinary skill in the dataprocessing arts to convey the substance of their work to others skilledin the art. As used herein, a “function” or a “routine” is aself-consistent sequence of operations or similar processing leading toa desired result. In this context, functions, algorithms, routines andoperations involve physical manipulation of physical quantities.Typically, but not necessarily, such quantities may take the form ofelectrical, magnetic, or optical signals capable of being stored,accessed, transferred, combined, compared, or otherwise manipulated by amachine. It is convenient at times, principally for reasons of commonusage, to refer to such signals using words such as “data,” “content,”“bits,” “values,” “elements,” “symbols,” “characters,” “terms,”“numbers,” “numerals,” or the like. These words, however, are merelyconvenient labels and are to be associated with appropriate physicalquantities.

Unless specifically stated otherwise, discussions herein using wordssuch as “processing,” “computing,” “calculating,” “determining,”“presenting,” “displaying,” or the like may refer to actions orprocesses of a machine (e.g., a computer) that manipulates or transformsdata represented as physical (e.g., electronic, magnetic, or optical)quantities within one or more memories (e.g., volatile memory,non-volatile memory, or a combination thereof), registers, or othermachine components that receive, store, transmit, or displayinformation.

As used herein any reference to “some embodiments” or “one embodiment”or “an embodiment” means that a particular element, feature, structure,or characteristic described in connection with the embodiment isincluded in at least one embodiment. The appearances of the phrase “inone embodiment” in various places in the specification are notnecessarily all referring to the same embodiment.

Some embodiments may be described using the expression “coupled” and“connected” along with their derivatives. For example, some embodimentsmay be described using the term “coupled” to indicate that two or moreelements are in direct physical or electrical contact. The term“coupled,” however, may also mean that two or more elements are not indirect contact with each other, but yet still co-operate or interactwith each other. The embodiments are not limited in this context.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a function,process, method, article, or apparatus that comprises a list of elementsis not necessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Further, unless expressly stated to the contrary,“or” refers to an inclusive or and not to an exclusive or. For example,a condition A or B is satisfied by any one of the following: A is true(or present) and B is false (or not present), A is false (or notpresent) and B is true (or present), and both A and B are true (orpresent).

In addition, use of the “a” or “an” are employed to describe elementsand components of the embodiments herein. This is done merely forconvenience and to give a general sense of the description. Thisdescription should be read to include one or at least one and thesingular also includes the plural unless it is obvious that it is meantotherwise.

Still further, the figures depict preferred embodiments of a computersystem 100 for purposes of illustration only. One of ordinary skill inthe art will readily recognize from the foregoing discussion thatalternative embodiments of the structures and methods illustrated hereinmay be employed without departing from the principles described herein.

Upon reading this disclosure, those of skill in the art will appreciatestill additional alternative structural and functional designs for aprocess management system and a method that uses an RFID detection andtracking system for managing or controlling process or productionoperations can be used as well or instead. Thus, while particularembodiments and applications have been illustrated and described, it isto be understood that the disclosed embodiments are not limited to theprecise construction and components disclosed herein. Variousmodifications, changes and variations, which will be apparent to thoseskilled in the art, may be made in the arrangement, operation anddetails of the method and apparatus disclosed herein without departingfrom the spirit and scope defined in the appended claims.

1. A method of controlling a manufacturing process associated with amanufacturing job order, comprising: identifying, by a command system, ajob order recipe associated with the manufacturing job order, whereinthe job order recipe identifies one or more material inputs to amanufacturing stage that implements a production machine to produce amanufactured product in accordance with the manufacturing job order,searching, by the command system, a database to identify one or moreradio frequency identification (RFID) tags that are physicallyassociated with each of the one or more material inputs; determining, bythe command system, a position of the one or more RFID tags; andcontrolling, by a process controller in communication with the commandsystem, operation of the production machine implemented by themanufacturing stage based upon whether the position of the one or moreRFID tags matches a location of the manufacturing stage as indicated bythe manufacturing job order.
 2. The method of claim 1, wherein the actof searching the database to identify the one or more RFID tagscomprises: searching the database to identify one or more RFID tagshaving one or more respective unique RFID tag numbers that correlate tothe one or more material inputs as specified by the job order recipe. 3.The method of claim 1, wherein the act of controlling the operation ofthe production machine comprises: generating a notification indicativeof the one or more material inputs being at an improper location whenthe position of the one or more RFID tags does not match the location ofthe manufacturing stage as indicated by the manufacturing job order. 4.The method of claim 1, wherein the act of controlling the operation ofthe production machine comprises: disabling operation of the productionmachine such that the one or more material inputs are not subjected tothe manufacturing stage when the position of the one or more RFID tagsdoes not match the location of the manufacturing stage as indicated bythe manufacturing job order.
 5. The method of claim 1, wherein the oneor more material inputs include (i) raw material used by the productionmachine to produce the manufactured product, or (ii) components of theproduction machine.
 6. The method of claim 1, further comprising:controlling, by the command system, an antenna to scan a region in whichthe manufacturing process occurs, the antenna having an associatedcoverage area; and resolving, by the command system, a location of theone or more RFID tags within the region that is less than the coveragearea of the antenna based on a signal transmitted by the one or moreRFID tags.
 7. The method of claim 1, further comprising: monitoringchanges in the position of the one or more RFID tags attached to each ofthe one or more material inputs over time.
 8. A method of monitoring amanufacturing process associated with a manufacturing job order having ajob order recipe, comprising: identifying, by a command system basedupon the job order recipe, (i) a first and a second manufacturing stage,(ii) a first material input used at the first manufacturing stage toproduce an intermediate output, and (iii) a second material input thatis the intermediate output, which is used at the second manufacturingstage to produce a manufactured product; identifying, by the commandsystem as indicated by the job order recipe, a first radio frequencyidentification (RFID) tag that is physically associated with the firstmaterial input and a second RFID tag that is physically associated withthe second material input; determining, by the command system, aposition of the first material input and a position of the secondmaterial input based upon a position of the first RFID tag and aposition of the second RFID tag, respectively; and indicating, by thecommand system, (i) whether the first material input is correctlylocated at the first manufacturing stage as specified by themanufacturing job order based upon the determined position of the firstRFID tag, and (ii) whether the second material input is correctlylocated at the second manufacturing stage as specified by themanufacturing job order based upon the determined position of the secondRFID tag.
 9. The method of claim 8, wherein the first RFID tag includesdata identifying the first material input, and wherein the second RFIDtag includes data identifying the intermediate output.
 10. The method ofclaim 8, further comprising: generating, by the command system, anotification indicative of the first or the second material input beingat an improper location when the first or the second material input isnot located at the first or the second manufacturing stage,respectively, as indicated by the manufacturing job order.
 11. Themethod of claim 8, further comprising: disabling operation of a firstproduction machine associated with the first manufacturing stage suchthat the first material input is not subjected to the firstmanufacturing stage when the first material input is not correctlylocated at the first manufacturing stage; and disabling operation of asecond production machine associated with the second manufacturing stagesuch that the second material input is not subjected to the secondmanufacturing stage when the second material input is not correctlylocated at the second manufacturing stage.
 12. The method of claim 8,further comprising: searching a database to identify the first andsecond RFID tags having one or more respective unique RFID tag numbersthat correlate to the first material input and the second materialinput, respectively, as specified by the job order recipe.
 13. Themethod of claim 8, further comprising: controlling, by the commandsystem, an antenna to scan a region in which the manufacturing processoccurs, the antenna having an associated coverage area; and resolving,by the command system, a location of the first and second RFID tagswithin the region that is less than the coverage area of the antennabased on a signal transmitted by the first and second RFID tags.
 14. Themethod of claim 13, further comprising: monitoring changes in theresolved location of the first and second RFID tags over time to trackmovement of the first material input and the second material input. 15.A command system for controlling a manufacturing process associated witha manufacturing job order, comprising: a database configured to store ajob order recipe associated with the manufacturing job order, the joborder recipe identifying one or more material inputs to a manufacturingstage that is used to produce a manufactured product as specified by themanufacturing job order; a processor configured to identify, from thejob order recipe stored in the database, one or more radio frequencyidentification (RFID) tags that are physically associated with the oneor more material inputs; and an RFID detection controller configured toperiodically monitor a manufacturing location that is co-located withthe manufacturing stage, to detect the one or more RFID tags at themanufacturing location, and to determine a position of the detected oneor more RFID tags within the manufacturing location, and wherein theprocessor is further configured to check, when the manufacturing joborder is executed, whether the position of the detected one or more RFIDtags matches a location associated with an input to the manufacturingstage as indicated by the manufacturing job order.
 16. The commandsystem of claim 15, wherein the RFID detection controller is furtherconfigured to control an antenna network, and to periodically monitorthe manufacturing location by operating an antenna within the antennanetwork to steer a beam through the manufacturing location.
 17. Thecommand system of claim 16, wherein the RFID detection controller isfurther configured to resolve a location of the one or more RFID tagswithin the manufacturing location to an area that is less than acoverage area of the antenna based on a signal transmitted by the one ormore RFID tags.
 18. The command system of claim 15, further comprising:a communication module configured to transmit a notification uponexecution of the manufacturing job order when the one or more RFID tagsare not located at the input to the manufacturing stage as indicated bythe manufacturing job order.
 19. The command system of claim 15, furthercomprising: a process controller configured to disable operation of aproduction machine implemented by the manufacturing stage when the oneor more RFID tags are not located at the input to the manufacturingstage as indicated by the manufacturing job order.
 20. The commandsystem of claim 15, wherein the RFID detection controller is furtherconfigured to monitor changes in the position of the detected one ormore RFID tags over time.